BMW 1983 K100 RS Manuals

Manuals and User Guides for BMW 1983 K100 RS. We have 1 BMW 1983 K100 RS manual available for free PDF download: Owners Workshop Manual

BMW 1983 K100 RS Owners Workshop Manual (237 pages)

Brand: BMW | Category: Motorcycle | Size: 33.52 MB

Contents
3
Introduction
5
Model Dimensions and Weights
8
Ordering Spare Parts
9
Location of Engine Number
9
Location of Frame Number
9
Safety
10
Fire
10
Asbestos
10
Fumes
10
Tools and Working Facilities
11
Maintenance and Minor Repair Tool Kit
12
Specialized Tools
12
Repair and Overhaul Toolkit
12
Fastening Systems
12
Spanner Size Comparison
13
Standard Torque Settings
13
Choosing and Fitting Accessories
14
Fairings and Windscreens
14
Luggage Racks or Carriers
15
Handlebars
15
Luggage
15
Crashbars
15
Electrical Equipment
16
Accessories
16
Fault Diagnosis
17
Starter Motor Not Rotating
18
No Fuel Flow to Engine
18
Fuel Not Reaching Cylinder
18
Engine Flooding
18
Weak Spark at Plug
19
Compression Low
19
Fuel/Air Mixture Incorrect
19
General Causes
19
Knocking or Pinking
20
Overheating
20
Clutch Operating Problems
20
Gear Selection Problems
20
Abnormal Engine Noise
21
Abnormal Transmission Noise
21
Jumping out of Gear
21
Other Noises
21
Exhaust Smokes Excessively
22
Poor Handling or Roadholding
22
Oil Pressure Indicator Lamp Goes on
22
Steering Bias to Left or Right
22
Abnormal Frame and Suspension Noise
23
Brake Problems
23
Handlebar Vibrates or Oscillates
23
Poor Front Fork Performance
23
Electrical Problems
24
Brakes Drag
24
Drum Brakes
24
Brake Pedal Pulsates in Operation
24
Battery Overcharged
25
Total Electrical Failure
25
Circuit Failure
25
Bulbs Blowing Repeatedly
25
Routine Maintenance
26
Specifications
26
Cycle Parts
26
Recommended Lubricants
26
Cleaning the Machine
27
Service Intervals
27
Additional Recommendations
27
Daily
27
Check the Tyres
28
Check the Engine Oil Level
28
Engine Oil Viscosity Selection Chart
28
Check the Fuel Level
29
Check the Coolant Level
29
Check the Controls
29
Rear Suspension Settings
29
Check the Battery
30
Minor Service
31
Change the Engine Oil and Filter
31
Check the Gearbox Oil Level
32
Check the Final Drive Case Oil Level
32
Lubricate the Controls and Stand Pivots
33
Gearbox Oil Level Dipstick
33
Check and Adjust the Valve Clearances
34
Checking the Valve Clearances
34
Adjusting the Valve Clearances with Service Tools
34
Adjusting the Valve Clearances Without Service Tools
36
Check and Adjust the Spark Plugs
36
Major Service
37
Final Inspection
37
Air Filter
37
Change the Gearbox Oil
38
Change the Final Drive Case Oil
38
Change the Front Fork Oil
38
Clean the Speedometer Impulse Transmitter
38
Renew the Air Filter Element
40
Check the Cooling System
40
Check and Adjust the Clutch
40
Renew the Spark Plugs
41
Check the Fuel System
41
Check and Overhaul the Brakes
41
Disc Brakes
41
Brake Fluid Renewal
43
Drum Rear Brake
44
Wheels
44
Front Wheel Bearings
44
Rear Wheel Bearings
44
Renew the Fuel Filter
45
Engine
46
General Description
49
Carrying out a Compression Test
49
Dismantling the Engine Unit
50
Removing the Engine Unit from the Frame
50
Dismantlinh the Engine Unit
51
General Procedures
52
Cylinder Head Cover
52
Crankshaft Cover
52
Cam Chain Cover
52
Camshafts and Cam Chain
54
Removing the Cylinder Head
55
Removing the Pistons and Connecting Rods
56
Method of Removing Gummed Piston Rings
58
Removing the Crankshaft
59
Removing Bearings and Oil Seals
60
Examination and Renovation
60
Bearings and Oil Seals
61
Engine Cases and Covers
61
Crankshaft and Camshaft Drive Mechanism
61
Cylinder Head
63
Valves, Valve Seats and Valve Guides
63
Cylinder Block
65
Pistons and Piston Rings
66
Connecting Rods and Big-End Bearings
66
Crankshaft and Main Bearings
67
Fabricated Small-End Bush Drawbolt Tool
67
Output/Balancer Shaft
68
Auxiliary Drive Shaft and Starter Clutch
72
Auxiliary Drive Shaft and Starter Clutch Components
73
Reassembling the Engine Unit
74
Refitting Bearings and Oil Seals
75
Refitting the Crankshaft
75
Refitting the Output/Balancer Shaft
76
Crankcae Lower Section
76
Refitting the Cylinder Head
81
Cylinder Head Bolt Tightening Sequence
81
Refitting the Camshafts and Setting the Valve Timing
82
Refitting the Auxiliary Drive Shaft Components and the Bellhousing
86
Refitting the Outer Covers
87
Refitting Ancillary Components
89
Refitting the Engine Unit to the Frame
89
Starting and Running the Rebuilt Engine
91
Taking the Rebuilt Machine on the Road
91
Clutch
92
Clutch Removal
92
Clutch Friction Plate
92
Torque Wrench Settings
92
Clutch Assembly
93
Clutch Dismantling
94
Clutch Examination and Renovation
94
Clutch Reassembly
95
Clutch Housing Locking Tool
95
Measuring Clutch Friction Plate Thickness
95
Clutch Release Mechanism
98
Side Stand Retracting Mechanism
98
Gearbox
101
Gearbox Lubrication
101
Gearbox General Description
102
Removing the Gearbox from the Frame
102
Gearbox Dismantling
103
Gearbox Housing
103
Removing and Refitting the Bearings and Seals
104
Gearbox Shafts
105
Input Shaft
105
Output Shaft
105
Layshaft
105
Checking and Resetting the Gearbox Shafts, Endfloat and Preload
109
Layshaft and Output Shaft
109
Gearbox Reassembly
110
Selector Drum and Forks
110
Cooling System
117
Coolant
117
Cooling System Draining
118
Cooling System Filling
118
Cooling System Flushing
118
Radiator Removal, Cleaning and Examination
119
Radiator Pressure Cap
121
Hoses and Connections
122
Cooling System Hoses
122
Thermostat
123
Water Pump
124
Cooling Fan
125
Cooling System Electrical Component
125
Coolant Temperature Sensor
125
Temperature Sensing Switch Unit
125
Coolant Overheat Warning Lamp
126
Fuel System and Lubrication
127
Fuel Tank Capacity
127
Recommended Fuel Grade
127
Fuel System Components
129
Precautions
130
Relieving Fuel System Pressure
131
Fuel System Fault Finding
131
Fuel Tank Removal and Refitting
132
Fuel Tank Components
135
Fuel Return Valve
135
Tank Insulation
135
Internal Hoses and Pipes
135
Fuel Gauge Sender Unit
136
Fuel Filter
136
Fuel Pump
136
Pressure Regulator
138
Fuel Pressure: Testing
138
Fuel Rail and Injectors
138
Air Filter Housing
140
Airflow Meter
141
Throttle Butterfly Assembly and Plenum Chamber
142
Fuel System Electrical Components
144
Fuel Injection Relay
144
Fuel Injection Control Unit
144
Fast Idle Speed Control Cable
145
Idle Speed and Throttle Cable
146
Throttle Butterfly Synchronization
146
Idle Mixture Adjustment
146
Mixture Adjustment and Checks Using an Exhaust Gas Analyser
147
Checking the Air Filter Element
147
Checking for Instruction System Air Leaks
147
Compensating for High Altitude
148
Recommended Fuel
148
Exhaust System
148
Oil Pump Removal
149
Oil/Water Pump
150
Oil Pressure Relief Valve
151
Oil Pump Pick-Up Filter Gauze
152
Oil Filter
152
Oil Pressure Warning Lamp
153
Ignition System
154
Precautions to be Observed When Checking the Ignition System
155
Ignition System Components
155
Ignition Control Unit
156
Ignition Trigger Assembly
156
Ignition HT Coils
157
Ignition HT Leads
158
Spark Plugs
158
Ignition System Fault Finding
158
Vacuum Switch
158
Frames and Forks
160
Front Forks
161
Front Forks Dismantling
162
Front Forks Examination and Renovation
164
Front Forks Reassembly
165
Front Forks Refitting
167
Front Forks Aligning the Damping Components
168
Steering Head Bearings
170
Steering Head Bearings Refitting
170
Fluidbloc Steering Damper
170
Fluidbloc Steering Damper Installation
170
Frame Examination and Renovation
171
Footrests General
171
Stands and Controls
171
Headlamp Surround
171
Fairing
172
Engine Spoiler/Belly Fairing
172
Fairing Installation
173
Seat Removal and Refitting
177
Bodywork Removal and Refitting
178
Rear Mudguard
178
Front Mudguard
178
Side Panels
178
Mirrors
179
Engine Protection Bars
179
Instruments
180
Panniers
180
Top Box
180
Final Drive and Rear Suspension
182
Final Drive Removal
183
Final Drive Assembly
184
Final Drive Refitting
186
Swinging Arm and Drive Shaft
187
Swinging Arm Examination
188
Final Drive Shaft
189
Swinging Arm and Drive Shaft Refitting
189
Rear Suspension Unit
190
Nivomat Suspension Unit
191
Wheels, Brakes and Tyres
193
Front Wheel
194
Rear Wheel
196
Wheel Bearings
197
Hydraulic Brake Overhaul
198
Caliper
199
Front Brake Master Cylinder
199
Brake Caliper
199
Rear Disc Brake Master Cylinder
201
Bleeding the Hydraulic Brake System
202
Rear Drum Brake
204
Tyres
205
Puncture Repair and Tyre Renewal
206
Tyre Valves
206
Wheel Balancing
207
Electrical System
208
Battery Examination
209
Alternator
210
Checking the Output
210
Alternator Removal and Refitting
210
Alternator Overhaul
212
Starter Motor
215
Starter Motor Overhaul
216
Starter System
217
Oil Pressure Warning Lamp Circuit
218
Gear Position Indicator Switch
218
Clutch Interlock Switch
218
Interlock Circuit Diode
218
Cold Start Device Indicator
219
Tail Lamp Bulb Monitoring Device
219
Switches
219
Fuyel Level Gauge Circuit
219
Relays
220
Turn Signal Relay
220
Horn
220
Bulbs
221
Headlamp and Parking Lamp
221
Radio
221
Turn Signal Lamps
222
Stop and Tail Lamp
222
Instrument Panel Bulbs
222
Wiring Diagram
225
Conversion Factors
231
Index
232

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BMW 1983 K100 RS Owners Workshop Manual (237 pages)

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