BMW R 80 GS Manuals

Manuals and User Guides for BMW R 80 GS. We have 1 BMW R 80 GS manual available for free PDF download: Repair Manual

BMW R 80 GS Repair Manual (169 pages)

Brand: BMW | Category: Motorcycle | Size: 10.5 MB

Contents
2
Summary of Main Groups
4
Fitting out Motor Cycle and Delivery Inspection
5
Fitting out Motor Cycle
7
Installing Windshield
7
Affixing Helmet Sticker
7
Tightening Handlebar Controls
7
Removing Battery
8
Filling Battery with Electrolyte
8
Charging Batteries
8
Maintenance and Inspection
9
Checking Topping up Brake Fluid
9
Performing Operational Check
9
Final Visual Inspection
9
Engine and Transmission
11
Running Gear
12
Tightening Cylinder Head Nuts
12
Checking/Adjusting End Play of Rocker Arm
13
Adjusting Valve Clearance
13
Testing Compression Pressure
14
Spark Plugs
14
Compression Pressure too Low
14
Compressino Pressure Constant
14
Renewing Air Filter
15
Cleaning Fuel Cocks
15
Electrode Gap
15
Checking Electrode Gap with Feeler Gauge or Spark Plug Gauge
15
Cleaning Carburetor Float Housing
16
Checking/Adjusting Clutch Play
16
Checking/Adjusting Firing Point
16
Synchronizing Carburetors Adjusting Cables
17
Checking/Setting Firing Point
17
Synchronizing Carburetors with out CO Measurement
18
Synchronizing Carburetors with CO Measurement
18
Synchronizing Carburetors with CO Measurement for Pas
18
Final Adjustment of the Throttle Cables
18
Changing Oil and Oil Filter in Engine
19
Changing Oil in Transmission
19
Changing Transmission Oil in Rear Wheel Drive
20
Changing Oil in Telescopic Fork
20
Checking Front Brake Pads for Wear/Renewing
21
Installing Brake Pads
21
Checking Brake Discs
22
Checking/Topping up Brake Fluid Level
22
Changing Brake Fluid
23
Bleeding Front Wheel Brake System
23
Checking Rear Brake Pads for Wear/Renewing Brake Shoe if Necessary
24
Checking/Adjusting Foot Brake Lever Play
25
Checking Rear Wheel for Tilt Play
25
Checking Front Wheel Bearing
25
Checking/Adjusting Steering Bearing Play
26
Greasing Clutch Cable Nipples
26
Adjusting Swing Arm Bearing Play
26
Battery Maintenance
26
Checking Nuts and Bolts for Tight Fit
27
Commissioning Battery
27
Fuel, Oil and Lubricants
30
Engine Oil Viscosity Diagram
30
Operating Materials
31
Service Data
31
Tightening Torque
32
Electrics
33
Removing and Installing Headlamp
35
Removing and Installing Headlight
35
Removing Side Section Instrument Carrier
36
Removing the Speedometer
36
Removing the Instrument Carrier
36
Removing the Headlight
36
Installing the Headlight
37
Installing the Instrument Carrier
37
Installing the Speedometer
37
Removing and Installing the Headlight
38
Installing Flashing Turn Indicator with Holder
38
Installing the Windscreen
38
Removing the Revolution Counter
39
Removing the Ignition Switch
39
Installing the Ignition Switch
40
Adjusting Headlamp
41
Adjusting Headlamp with Beam Adjuster
41
Removing and Installing Turn Signals
42
Removing and Installing Rear Light
42
Removing and Installing Speedometer
42
Removal Display Panel with Ignition Lock
43
Disassembling and Assembling, Installing Display Panel
43
Removing and Installing Handlebar Controls
44
Testing Operation of Alternator, Regulator and Diode Plate
44
Quick Test of Alternator and Regulator
44
Removing and Installing Battery
45
Removing and Installing Fuse Box
45
Removing, Testing and Installing Relays
46
Testing Operation of Turn Signal Relay
46
Testing Operation of Starter Relay
46
Testing Diode of Starter Relay
46
Removing and Installing Regulator
47
Removing and Installing Ignition Control Unit
47
Removing, Testing and Installing Ignition Coil
47
Removing, Testing and Installing Diode Plate
48
Removing, Installing Ignition Trigger
48
Replacing Carbon Brushes
48
Removing, Testing, Disassembling and Assembling Alternator
49
Testing Alternator
49
Testing Starter
50
Disassembling Stator
50
Assembling Stator
50
Installing Alternator
50
Removing Starter
51
Disassembling Starter
51
Removing and Installing Switch for Idle Display
52
Removing and Installing Oil Pressure Switch
52
Assembling Starter
52
Installing Starter
52
Removing and Installing Rear Stop Light Switch
53
Removing and Installing Front Stop Light Switch
53
Removing and Installing Clutch Switch
53
Removing and Installing Horn
53
Removing and Installing Chassis Cable Harness Section
54
Removing and Installing Rear Cable Harness Section
54
Troubleshooting
55
Brake System
58
Removing Front Wheel Brake
60
Removing Brake Caliper
60
Removing Front Wheel
60
Removing Brake Disc
60
Disassembling Brake Caliper GS
61
Assembling Brake Caliper
61
Removing and Installing Front Brake Pads
62
Stripping down R 100R Brake Caliper
62
Assembling R 100R Brake Caliper
63
Removing Brake Line
63
Removing Brake Fluid Reservoir and Master Brake Cylinder
64
Disassembling/Assembling Brake Fluid Reservoir/ Master Brake Cylinder
64
Installing Front Wheel Brake
65
Installing Brake Disc
65
Installing Brake Caliper
65
Removing Rear Wheel Brake
66
Installing Brake Line
66
Removing Rear Wheel
66
Removing Brake Shoes
67
Removing Brake Lever
67
Installing Rear Wheel Brake
68
Removing Foot Brake Lever
68
Installing Brake Key and Brake Lever
68
Installing Brake Shoes
68
Adjusting Foot Brake Lever Play
69
Suspension
70
Replacing Wheel Bearing
73
Removing Handlebars
74
Disassembling and Assembling Grip Units
74
Disassembling Right Grip Unit
74
Assembling Right Grip Unit
74
Disassembling Left Grip Unit
75
Assembling Left Grip Unit
75
Removing and Installing, Disassembling and Assembling Telescopic Fork
76
Stripping down Telescopic Fork
79
Measuring Telescopic Fork Alignment
80
Examining Stanchions
80
Examining Bottom Fork Bridge
80
Examine Parallelisms of the Stancions
80
Assembling Telescopic Fork
81
Assembling Stanchions
82
Removing and Installing Head Bearing
83
Removing and Installing Bottom Taper Roller Bearing
83
Examining Front Frame Section
84
Installing Telescopic Fork
85
Installing Handlebars
86
Installing Front Wheel
87
Measuring Track Alignment
87
Removing and Installing Spokes
89
Examining Rims for Runout, Centering
89
Static Wheel Balancing
90
Centering Lateral Runout
90
Removing, Disassembling and Assembling Rear Spring Strut
91
Installing the Input Bevel Pinion
94
Installing Crown Wheel
95
Adjusting Tooth Backlash
95
Checking Tooth Contact Pattern
96
Installing the Housing Cover
96
Shimming the Housing Cover
96
Removing and Installing Taper Roller Bearings
97
Installing Rear Wheel Drive
98
Installing Spring Strut
98
Frame Attachments
99
Installing Rear Wheel
99
Removing and Installing Rear Mudguard
101
Removing Rear Frame Section
101
Removing and Installing Side Stand
102
Removing and Installing Cylinder Guard
102
Disassembling Rear Frame Section
102
Removing and Installing Kickstand
103
Removing and Disassembling Foot Rests
103
Removing and Installing Air Filter Box
104
Installing Foot Rests
104
Removing Air Filter Box
104
Exhaust System
105
Removing and Installing Battery Mount
105
Removing and Installing Steering Lock
105
Removing and Installing Exhaust System
107
Removing Front Silencer and Exhaust Manifold
108
Installing Front Silencer and Exhaust Manifold
108
Installing Main Silencer
108
Gearbox
109
Removing Transmission
111
Disassembling Transmission
112
Removing and Installing Kick Starter
114
Removing Bearing Block for Shift Discs
114
Disassembling Bearing Block
114
Assembling Bearing Block
114
Removing and Disassembling Input Shaft
115
Assembling Input Shaft
115
Removing Output and Intermediate Shafts
116
Disassembling Output Shaft
117
Assembling Output Shaft
117
Replacing Radial Seal for Input Shaft
117
Replacing Roller Bearing of Input Shaft
117
Assembling Transmission
118
Calculating Thickness of Spacer Ring for End Play
118
Installing Transmission
120
Troubleshooting Transmission
121
Disassembling and Assembling Gear Shift Linkage
121
Installing Shift Lever
121
Clutch
122
Removing and Installing Clutch
124
Engine
126
Fuel Preparation
128
Removing and Disassembling Fuel Tap
128
Removing and Installing Bowden Cable for Cold Start Device
128
Removing and Installing Bowden Cables for Throttle Control
129
Removing Carburetor
129
Disassembling Carburetor
130
Removing Nozzle Set
130
Assembling Carburetor
131
Removing Shed Fuel System
132
Troubleshooting Shed-System
133
System Diagram of Shed Fuel System
133
Removing Engine
134
Disassembling Engine
135
Disassembling Cylinder Head
135
Checking Valve Guide for Wear
136
Reaming out Valve Guide
137
Replacing Valve Guides
137
Installing Valves
138
Removing Cylinder
139
Removing Conrod
139
Examining and Repairing Conrod
140
Examining Conrod for Parallelism and Twisting
141
Removing Oil Pump
142
Assembling Oil Pump
142
Replacing Radial Seal for Crank Shaft Seal
142
Removing Chain Box Cover
143
Replacing Radial Seal for Crankshaft Seal
144
Removing Camshafts
144
Examining Camshaft
144
Removing Crank Shaft
145
Determining Crankshaft Bearing Play
145
Removing Crankshaft Bearing
146
Removing Oil Sump and Intake Bell
146
Removing and Installing Bent Cover
146
Removing and Installing Bypass Valve
146
Assembling Engine
147
Installing Crank Shaft Bearing Bush in Engine Housing
147
Installing New Crankshaft Bearing Bush in Bearing Cover
147
Examining Conrod Bearing Play
148
Installing Crankshaft
148
Installing Camshaft
149
Attaching Chain Box Cover
150
Installing Oil Pump
150
Installing Piston
150
Installing Cylinder
151
Attaching Cylinder Head
151
Installing Engine
152
Installing Intake Bell and Oil Sump
152
Removing and Disassembling Oil Cooler
153
Troubleshooting Engine
154
Insufficient Compression Pressure
154
Engine Does Not Start Clearly or Not at All
154
Engine Pings
154
Technical Data
155
Engine Does Not Accelerate Properly
155
Engine Curs out
155
Engine Oil Vicosity Diagram
158

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BMW R 80 GS Repair Manual (169 pages)

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