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BMW R1100RT R1100RS R850 / 1100GS R850 / 1100R * DIY SERVICE / REPAIR / WORKSHOP MANUAL (YEARS: 1994 1995 1996 1997 1998 1999 2000 2001 94 95 96 97 98 99 00 01) - DOWNLOAD NOW!!
( VERY HIGH QUALITY FACTORY SERVICE MANUAL - PDF DOWNLOAD !! )
SERVICE MANUAL COVERS:
===================
R1100RT, R1100RS, R850 1100GS, R850 1100R, R 1100 RT, R 1100 RS, R 850 1100 GS, R 850 1100 R,R1100 RT, R1100 RS, R850 1100 GS, R 850 1100 R,R 1100RT, R 1100RS, R850 1100GS, R850 1100R
FOR PRODUCTION YEARS:
=================
1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001 ( 94 95 96 97 98 99 00 01 )
CONTENTS:
=======
00 Maintenance and general instructions
11 Motor
12 Engine electrics
13 Fuel preparation and control
16 Fuel tank and lines
18 Exhaust system
21 Clutch
23 Gearbox
31 Front fork
32 Steering
33 Rear wheel drive
34 Brakes
36 Wheels and tyres
46 Frame
51 Equipment
52 Seat
61 General electrical equipment
62 Instruments
63 Lights
INDEPTH CONTENTS / INDEX :
=======================
( SOME OF THE TOTAL CONTENTS ARE SHOWN BELOW....(WITH ACTUAL PAGE NOS.. ALL ARE NEATLY BOOKMARKED, INDEXED AND SEARCHABLE FOR EASY NAVIGATION ... )
Contents Page
00
Tightening torques R 1100 RS / R 1100 RT ....................................................................3
Tightening torques R 850/1100 GS und R 850/1100 R ...........................................12
Operating materials ...................................................................................................................21
Key to maintenance intervals ...................................................................................................22
Change engine oil, renew oil filter element .................................................................22
(Inspection I, II, III, IV) ........................................................................................................................22
Change the oil in the gearbox and rear wheel drive ...............................................23
(Inspection I, III, IV) ............................................................................................................................23
Changing oil in gearbox .............................................................................................................23
Changing oil in rear wheel drive .............................................................................................23
Checking battery acid level/topping up if necessary, cleaning/greasing
battery posts ................................................................................................................................24
(Inspection III, IV) ...............................................................................................................................24
Renewing air cleaner ...............................................................................................................24
(Inspection III) ...................................................................................................................................24
Renewing fuel filter ...................................................................................................................25
(Inspektion III) ...................................................................................................................................25
Checking/renewing spark plugs ........................................................................................29
(Inspection II, III) ...............................................................................................................................29
Taking up slack at cylinder heads ....................................................................................29
(Inspection I) .....................................................................................................................................29
Checking/adjusting valve operating clearances ......................................................30
(Inspection I, II, III) .............................................................................................................................30
Adjusting Poly-V belt ................................................................................................................31
(Inspection I, II, III) .............................................................................................................................31
Renewing Poly-V belt
(40 000 km/24 000miles) ..........................................................................................................31
(renew maintenance-free belts every 60 000 km/36 000 miles) .........................................................31
Checking brake pads and discs for wear/renewing ...............................................32
(Inspection III) ...................................................................................................................................32
(ABS: Inspection II, III) .......................................................................................................................32
00 Maintenance and general instructions
00.2
Contents Page
Checking brake pads for wear ................................................................................................32
Renewing brake pads front brake ......................................................................................32
[RS] Renewing brake pads - rear brake ..............................................................................33
[GS/R/RT] Renewing brake pads - rear brake .................................................................33
Checking brake discs for wear ...............................................................................................33
Checking brake fluid level/topping up ............................................................................33
(Inspection III) ...................................................................................................................................33
Bleeding/renewing the brake fluid using the handbrake lever/
brake pedaln ................................................................................................................................34
(Inspection III, IV) ...............................................................................................................................34
Bleeding front brake circuit/renewing fluid ........................................................................34
Bleeding rear brake circuit/renewing brake fluid ............................................................34
Grease the centre stand [RS], side stand and clutch cable nipple ................35
(Inspection II, III, IV) ...........................................................................................................................35
[RS] Cleaning and greasing the windshield adjusting shaft ...............................35
(Inspection III) ...................................................................................................................................35
[RS] Grease front suspension strut at its lower attachment lug
(version with plain bearing only) ........................................................................................35
(Inspection II, III) ...............................................................................................................................35
Checking/adjusting clutch operating clearance ......................................................36
(Inspection I, II, III) .............................................................................................................................36
Checking tightness of rear wheel studs ........................................................................37
(Inspection I) .....................................................................................................................................37
[RS] Check tightness of screws at adjustable handlebar ....................................37
(Inspection I) .....................................................................................................................................37
[R] Check steering damper ...................................................................................................37
(Inspection II, III) ...............................................................................................................................37
Taking up slack on hose clips at intake stub pipen ................................................37
(Inspection I, III) ................................................................................................................................37
Checking front wheel bearings/
checking tilt play at rear wheel ..........................................................................................37
(Inspection III) ...................................................................................................................................37
Checking swinging arm bearings, adjusting if necessary ...................................37
(Inspection I, II, III) .............................................................................................................................37
Checking/adjusting throttle synchronisation and CO emission value ..........38
(Inspection I, II, III, IV) ........................................................................................................................38
Final inspection with road safety and functional check .......................................42
(Inspection I, II, III, IV) ........................................................................................................................42
Contents Page
11
Technical Data ............................................................................................................................... 5
Sectioned drawing of engine ...............................................................................................37
Lubricating oil circuit ...............................................................................................................38
Coolant circuit ..............................................................................................................................39
Cooling oil circuit (with oil thermostat) ..........................................................................40
Removing engine ........................................................................................................................41
Fitting auxiliary frame .........................................................................................................................52
Take off auxiliary frame. .....................................................................................................................53
Dismantling engine ....................................................................................................................54
Removing cylinder head cover ................................................................................................55
Locking the engine in the TDC position ..............................................................................56
TDC on ignition stroke: ......................................................................................................................56
Removing and installing chain tensioner ............................................................................57
Assembly specification for timing chain tensioner: ............................................................................57
Removing valve gear holder .....................................................................................................58
Dismantling/reassembling valve gear holder ....................................................................59
Removing cylinder head ............................................................................................................61
Dismantling, checking, repairing and re-assembling cylinder head ......................62
Removing and installing valves ..........................................................................................................62
Removing valve stem seals ...............................................................................................................62
Checking valves for wear ..................................................................................................................63
Remachining valve seat .....................................................................................................................63
Checking and repairing cylinder head ...............................................................................................63
Checking valve guide for wear ...........................................................................................................63
Replacing valve guides ......................................................................................................................64
Installing valve and valve stem seal ...................................................................................................65
Removing cylinder barrel ...........................................................................................................66
Removing/dismantling piston ..................................................................................................66
Checking pistons and cylinders .............................................................................................67
Assemble pistons .........................................................................................................................67
11 Motor
11.2
Contents Page
Removing/installing conrod ......................................................................................................68
Removing and installing alternator cover with engine installed ...............................69
Removing alternator mount cover .........................................................................................69
Renewing radial shaft seal in alternator mount cover ...................................................70
Renewing radial shaft seal for rotary breather .................................................................70
Removing auxiliary-shaft drive ................................................................................................71
Removing oil pump ......................................................................................................................72
Oil temperature regulator ..........................................................................................................72
Removing radial shaft seal on crank-shaft with engine installed .............................73
Dismantling crankcase ...............................................................................................................74
Removing crankshaft, auxiliary shaft and timing chain tensioning and
slide rails ..........................................................................................................................................76
Removing and installing oil pick-up basket .......................................................................77
Replacing oil level sight glass .................................................................................................77
Removing conrods .......................................................................................................................77
Checking conrods ........................................................................................................................77
Measuring main and big end bearing play .........................................................................78
easuring radial bearing play ...............................................................................................................78
Install main bearings ....................................................................................................................79
Measuring axial bearing play .............................................................................................................79
Measuring big end bearing play .............................................................................................80
Assembling engine ....................................................................................................................81
Installing conrod ............................................................................................................................81
Installing crankshaft .....................................................................................................................82
Installing timing chain tensioning and slide rails .............................................................82
Installing auxiliary shaft/timing chains ..................................................................................82
Assembling engine block ..........................................................................................................83
Installing radial seal on crankshaft ........................................................................................85
Installing clutch housing ............................................................................................................86
Installing oil pump .........................................................................................................................87
11.3
Contents Page
Installing auxiliary shaft drive ...................................................................................................88
Installing pistons ............................................................................................................................89
Installing cylinders ........................................................................................................................90
Installing cylinder head ...............................................................................................................91
Adjusting valve clearances .......................................................................................................92
Installing right cylinder head ....................................................................................................93
Adjustment specification ...................................................................................................................93
Installing left cylinder head .......................................................................................................94
Adjustment specification ...................................................................................................................94
Installing alternator mount cover ............................................................................................96
Installing magnetic gate/belt pulley ......................................................................................96
Timing the ignition .............................................................................................................................97
Installing alternator .......................................................................................................................98
Installing engin ............................................................................................................................99
Contents Page
12
Technical Data ............................................................................................................................... 3
Removing and installing coil and ignition lead ............................................................7
Checking ignition coil resistance .............................................................................................7
Removing and installing alternator ....................................................................................8
Adjusting procedure for Poly-V belt: ....................................................................................................9
Dismantling/reassembling alternator ..............................................................................10
Checking alternator ......................................................................................................................11
Checking armature for short to ground (earth) ................................................................11
Removing and installing starter motor ...........................................................................12
Dismantling/reassembling starter motor ......................................................................13
Renewing carbon brushes ........................................................................................................13
Checking starter motor ..............................................................................................................13
Checking starter relay .................................................................................................................13
Removing and installing magnetic gate ........................................................................14
Timing the ignition ........................................................................................................................15
Contents Page
13
Technical Data ............................................................................................................................... 3
Removing and installing air cleaner ...................................................................................7
Removing and installing throttle stub pipe ....................................................................8
Removing and installing injectors ............................................................................................9
Removing and installing Motronic control unit ...........................................................9
Contents Page
16
Technical Data ............................................................................................................................... 3
Removing and installing fuel tank .......................................................................................7
Removing and installing fuel filter, fuel pump and fuel level sensor ...............9
Removing and installing fuel filter ..........................................................................................10
Removing and installing fuel pump and fuel level sensor ...........................................10
Checking fuel pump pressure .................................................................................................11
Removing and installing fuel distributor and pressure regulator ....................11
Removing and installing exhaust system ........................................................................3
Removing and installing muffler (silencer) ............................................................................3
Removing and installing front exhaust pipes ......................................................................4
Technical Data ............................................................................................................................... 3
Removing and installing clutch ............................................................................................7
Removing clutch ..............................................................................................................................9
Installing clutch ...............................................................................................................................9
Adjusting clutch operating clear-ance ...........................................................................
Contents Page
23
Technical Data ............................................................................................................................... 3
Gearbox - sectioned drawing ................................................................................................7
Removing and installing clutch bear-ing/thrust rod/release lever ...................9
Removing and installing gear shift pedal ......................................................................10
Removing gearbox .....................................................................................................................10
Dismantling/reassembling .....................................................................................................12
Replacing shaft seal on neutral switch ................................................................................12
Removing gearbox cover ..........................................................................................................13
Removing selector drum ............................................................................................................14
Removing gearbox shafts .........................................................................................................15
Removing and installing input shaft sealing ring at housing end ............................15
Removing/dismantling/reassembling selector shaft .....................................................16
Removing and installing detent lever .................................................................................................17
Removing and installing shift pawls ...................................................................................................17
Removing and installing torsion spring ..............................................................................................17
Removing and installing selector shaft seal ......................................................................17
Removing deep-groove ball bearing from selector drum ...........................................18
Shimming selector drum ...................................................................................................................18
Removing taper roller bearing race from input shaft and roller bearing from
idler shaft .........................................................................................................................................18
Installing deep-groove ball bearing on selector drum ..................................................19
Installing taper roller bearing race on input shaft and roller bearing for
idler shaft .........................................................................................................................................19
Removing and installing deep-groove ball bearing and race/roller bearing for
idler shaft .........................................................................................................................................20
Dismantling/reassembling input shaft ..................................................................................21
Disassembling/assembling input shaft (Clean Bearing) ...............................................23
23 Gearbox
23.2
Contents Page
Dismantling/reassembling output shaft ...............................................................................25
Removing deep-groove ball bearing ..................................................................................................25
Removing spur gears ........................................................................................................................26
Installing spur gears ..........................................................................................................................27
Installing gearbox shafts ............................................................................................................29
Removing and installing output shaft seal .........................................................................30
Installing selector shaft ...............................................................................................................31
Installing selector forks ...............................................................................................................32
Installing selector drum ..............................................................................................................32
Shimming gearbox shafts ..........................................................................................................33
Measuring shaft bearing play .............................................................................................................33
Measuring gearbox cover ..................................................................................................................34
Shimming the gearbox shafts (without Clean Bearing) .........................................35
Example ............................................................................................................................................35
Shimming the gearbox shafts (with Clean Bearing) ................................................35
Example ............................................................................................................................................35
Removing and installing taper roller bearing race ..........................................................36
Checking friction coefficient of input shaft taper roller bearing ................................36
Installing gearbox cover .............................................................................................................37
Removing and installing input shaft seal at housing cover end ...............................38
Completing assembly of gearbox ..........................................................................................39
Installing gearbox .......................................................................................................................40
Contents Page
31
Technical Data ............................................................................................................................... 3
Removing and installing telescopic fork .........................................................................7
Removing and installing telescopic fork without fork bridge .......................................7
[RS] Removing and installing fork bridge .............................................................................8
[GS/R/RT] Removing and installing fork bridge .................................................................8
Removing and installing pot-type joints ...............................................................................................9
Removing and installing ball thrust bearing .......................................................................................10
Removing and installing slider tube bridge .......................................................................11
Removing and installing ball joint ......................................................................................................11
[RS] Checking ball joint friction ...............................................................................................11
[GS/R/RT] Checking ball joint/ball thrust bearing friction ...........................................11
Assembly specification for telescopic fork: ........................................................................................12
Dismantling/reassembling telescopic fork ..................................................................13
Dismantling telescopic fork ......................................................................................................13
Assembling telescopic fork ......................................................................................................14
Measuring telescopic fork .....................................................................................................14
Check slider tube bridge ...................................................................................................................14
Checking runout of fixed tube ...........................................................................................................14
Removing and installing leading link ...............................................................................15
Dismantling/reassembling leading link ..........................................................................15
Removing and installing front suspension strut ........................................................16
[R] Removing and installing steering damper ............................................................16
Removing and installing ball head .........................................................................................16
Checking the steering damper ...............................................................................................16
Contents Page
32
Technical Data ............................................................................................................................... 3
Removing and installing left handlebar fitting .............................................................7
With heated handlebar grips ................................................................................................................7
Without heated handlebar grips ...........................................................................................................7
Removing and installing right handlebar fitting ..........................................................8
With heated handlebar grips ................................................................................................................8
Without heated handlebar grips ...........................................................................................................8
[RS] Removing and installing handlebar .........................................................................9
[GS/R/RT] Removing and installing handlebar ..........................................................10
Removing and installing wire cable distributor block ...........................................11
Removing and installing throttle cable ..........................................................................12
With wire cable distribution block ......................................................................................................13
Removing and installing cold-start cable .....................................................................14
With wire cable distribution block ......................................................................................................14
Removing and installing clutch cable .............................................................................15
Technical Data ............................................................................................................................... 3
Rear wheel drive-sectioned drawing ................................................................................7
Removing, dismantling, reassembling and installing rear wheel drive ..........9
Removing rear wheel drive .........................................................................................................9
Removing input bevel pinion .....................................................................................................9
Disassembling input bevel pinion ..........................................................................................11
Removing needle roller bearing for input bevel pinion .......................................................................12
Installing needle roller bearing for input bevel pinion .........................................................................12
Assembling input bevel pinion ................................................................................................13
Installing input bevel pinion ......................................................................................................14
Removing and installing taper roller bearing in rear wheel drive .............................15
Removing crown wheel ..............................................................................................................16
Installing crown wheel ................................................................................................................17
Checking/adjusting backlash ..................................................................................................18
Checking tooth contact pattern .............................................................................................19
Shimming housing cover ...........................................................................................................20
Installing housing cover .............................................................................................................20
Installing splined element ..........................................................................................................20
Installing rear wheel drive ..........................................................................................................21
Removing, dismantling, reassembling and installing rear swinging arm ....23
Removing rear swinging arm ...................................................................................................23
Removing and installing taper roller bearing ....................................................................23
Removing and installing flexible gaiter ................................................................................24
Removing drive shaft ..................................................................................................................24
Checking universal joint for wear .......................................................................................................24
Installing drive shaft .....................................................................................................................24
Installing rear swinging arm .....................................................................................................25
Removing and installing suspension strut ...................................................................26
Contents Page
34
Technical Data ............................................................................................................................... 3
Removing and installing front brake caliper .................................................................7
Dismantling and assembling front brake caliper ........................................................8
Dismantling front brake caliper .................................................................................................8
Assembling front brake caliper .................................................................................................8
Removing and installing rear brake caliper ...................................................................9
[RS] Dismantling and assembling rear brake caliper .............................................10
Dismantling rear brake caliper ................................................................................................10
Assembling rear brake caliper ................................................................................................11
[GS/R/RT] Dismantling and re-assembling rear brake caliper .........................12
Dismantling rear brake caliper ................................................................................................12
Assembling rear brake caliper ................................................................................................12
Removing and installing front brake disc .....................................................................13
[RS] Removing and installing rear brake disc (attached to rear wheel
drive) .................................................................................................................................................14
[GS/R] Removing and installing rear brake disc (attached to rear wheel
hub) ...................................................................................................................................................14
[RT/R] Removing and installing rear brake disc (attached to rear wheel
drive) .................................................................................................................................................15
[RS] Removing and installing front ABS sensor ........................................................16
[GS/R] Removing and installing front ABS sensor ...................................................17
[RT] Removing and installing front ABS sensor ........................................................18
[ABS] Adjusting front sensor gap ......................................................................................19
Marking sensor wheel .................................................................................................................19
Checking and adjusting sensor gap ....................................................................................19
[RS] Removing and installing rear ABS sensor .........................................................20
[GS/R/RT] Removing and installing rear ABS sensor ............................................21
34 Brakes
34.2
Contents Page
[RS] Adjusting rear ABS sensor gap ................................................................................22
Marking sensor wheel .................................................................................................................22
Checking and adjusting sensor gap ....................................................................................22
[GS/R/RT] Adjusting rear ABS sensor gap ...................................................................23
Marking sensor wheel .................................................................................................................23
Checking and adjusting sensor gap ....................................................................................23
Removing, installing, dismantling and assembling front brake master
cylinder ............................................................................................................................................24
Adjusting specification for handbrake lever .......................................................................................24
Removing and installing rear brake master cylinder ..............................................25
Checking and adjusting relief clear-ance of piston rod ...............................................25
Removing and installing brake pedal ..............................................................................26
Removing and installing ABS unit .....................................................................................27
Removing the ABS unit ..............................................................................................................28
Installing the ABS unit ................................................................................................................28
Removing and installing ABS relay and relay base .................................................29
Removing ABS relay ....................................................................................................................29
Installing the ABS relay ..............................................................................................................29
Removing ABS relay base ........................................................................................................30
Installing the ABS relay base ...................................................................................................30
Removing and installing brake line (with ABS) ..........................................................32
Removing and installing front ABS brake line ..................................................................32
Removing and installing rear ABS brake line .............................................................33
Technical Data ............................................................................................................................... 3
Removing and installing front wheel .................................................................................7
Removing front wheel ...................................................................................................................7
Installing front wheel ......................................................................................................................7
Removing and installing wheel bearings ..............................................................................8
[RS/R/RT] Removing and installing rear wheel (cast alloy) ................................10
Removing rear wheel ..................................................................................................................10
Installing rear wheel .....................................................................................................................10
[GS/R] Removing and installing rear wheel (spoked) ............................................11
Removing rear wheel ..................................................................................................................11
Installing rear wheel .....................................................................................................................11
Static balancing of front wheel/rear wheel ..................................................................12
Checking front/rear wheel rim for runout .....................................................................13
[GS/R (spoked wheel)] Removing and installing spokes .....................................14
[GS/R (spoked wheel)] Centering wheel rim ...............................................................14
Centering horizontal runout .....................................................................................................14
Technical Data ............................................................................................................................... 3
General view, frame ....................................................................................................................7
[RT] General view of fairing sections ................................................................................8
[RT] Removing and installing front mudguard .............................................................9
[RT] Removing and installing fairing sections ............................................................10
[RT] Removing and installing wind-shield ....................................................................11
[RT] Removing and installing inner fairing panel ......................................................12
[RT] Removing and installing upper section of fairing ..........................................13
[RT] Removing and installing fairing holder ................................................................14
[RT] Removing and installing luggage rack/case holder .....................................15
[RT] Removing and installing rear fairing .....................................................................16
[RT] Removing and installing number plate mount ................................................17
[RT] Removing and installing lower rear section .....................................................18
[RT/GS/R] Removing and installing center stand ....................................................19
Removing and installing side stand .................................................................................20
[RT] Removing and installing left footrest plate ........................................................21
[RT] Removing and installing right footrest plate ....................................................22
[RT] Removing and installing frame .................................................................................23
[RS] Removing and installing front mudguard ...........................................................24
[RS] Removing and installing side sections of fairing ...........................................25
[RS] Removing and installing side sections of full fairing ...................................26
[RS] Removing and installing wind-shield ....................................................................27
[RS] Removing and installing adjustable windshield .............................................28
[RS] Removing and installing inner fairing panel .....................................................29
[RS] Removing and installing top section of fairing ................................................30
[RS] Removing and installing fairing holder ................................................................31
46 Frame
46.2
Technica Data................................................................................................................................ 3
[RT] Removing and installing headlight ...........................................................................7
Adjusting headlight .........................................................................................................................7
[RS] Removing and installing headlight ...........................................................................8
Adjusting headlight .........................................................................................................................8
[GS] Removing and installing headlight ...........................................................................9
Adjusting headlight .......................................................................................................................10
[GS] Removing and installing front flashing turn indicator .................................10
[R] Removing and installing headlight ............................................................................10
Adjusting headlight .......................................................................................................................10
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DESCRIPTION:
=========
COVERS ALL MODELS & ALL REPAIRS A-Z
THIS IS NOT GENERIC REPAIR INFORMATION! IT IS VEHICLE SPECIFIC. THIS IS THE EXACT SAME MANUAL USED BY TECHNICIANS AT THE DEALERSHIPS TO MAINTAIN, SERVICE, DIAGNOSE AND REPAIR YOUR VEHICLE.
COMPLETE STEP-BY-STEP INSTRUCTIONS, DIAGRAMS, ILLUSTRATIONS, WIRING SCHEMATICS, AND SPECIFICATIONS TO COMPLETELY REPAIR YOUR VEHICLE WITH EASE!
YOU GET EVERYTHING YOU WILL EVER NEED ON ONE EASY-TO-USE CD-MANUAL. NO MORE FLIPPING THROUGH BOOKS TO FIND WHAT YOU NEED. PRINT ONLY THE PAGES AND DIAGRAMS YOU REQUIRE. NO MORE GREASY PAGES OR TORN LOST PAPER MANUALS AGAIN.
ALL PAGES ARE PRINTABLE, SO PRINT OFF WHAT YOU NEED & TAKE IT WITH YOU TO YOUR VEHICLE OR WORKSHOP. YOU CAN BLOW-UP IMAGES AND THEN PRINT OFF ENLARGED COPIES!
FACTORY HIGHLY DETAILED REPAIR MANUALS, WITH COMPLETE INSTRUCTIONS AND ILLUSTRATIONS, WIRING SCHEMATICS AND DIAGRAMS TO COMPLETELY SERVICE AND REPAIR YOUR VEHICLE.
ALL MANUALS ARE WINDOWS VISTA32 and 64, XP, ME, 98, NT, 2000 COMPATIBLE AND WORK WITH MAC!
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RELATED KEYWORDS:
==============
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