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BMW R 80 GS Repair Manual

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Table Of Contents

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Table of Contents

Contents
Summary of Main Groups
Fitting out Motor Cycle and Delivery Inspection
Fitting out Motor Cycle
Installing Windshield
Affixing Helmet Sticker
Tightening Handlebar Controls
Removing Battery
Filling Battery with Electrolyte
Charging Batteries
Maintenance and Inspection
Checking Topping up Brake Fluid
Performing Operational Check
Final Visual Inspection
Engine and Transmission
Running Gear
Tightening Cylinder Head Nuts
Checking/Adjusting End Play of Rocker Arm
Adjusting Valve Clearance
Testing Compression Pressure
Spark Plugs
Compression Pressure too Low
Compressino Pressure Constant
Renewing Air Filter
Cleaning Fuel Cocks
Electrode Gap
Checking Electrode Gap with Feeler Gauge or Spark Plug Gauge
Cleaning Carburetor Float Housing
Checking/Adjusting Clutch Play
Checking/Adjusting Firing Point
Synchronizing Carburetors Adjusting Cables
Checking/Setting Firing Point
Synchronizing Carburetors with out CO Measurement
Synchronizing Carburetors with CO Measurement
Synchronizing Carburetors with CO Measurement for Pas
Final Adjustment of the Throttle Cables
Changing Oil and Oil Filter in Engine
Changing Oil in Transmission
Changing Transmission Oil in Rear Wheel Drive
Changing Oil in Telescopic Fork
Checking Front Brake Pads for Wear/Renewing
Installing Brake Pads
Checking Brake Discs
Checking/Topping up Brake Fluid Level
Changing Brake Fluid
Bleeding Front Wheel Brake System
Checking Rear Brake Pads for Wear/Renewing Brake Shoe if Necessary
Checking/Adjusting Foot Brake Lever Play
Checking Rear Wheel for Tilt Play
Checking Front Wheel Bearing
Checking/Adjusting Steering Bearing Play
Greasing Clutch Cable Nipples
Adjusting Swing Arm Bearing Play
Battery Maintenance
Checking Nuts and Bolts for Tight Fit
Commissioning Battery
Fuel, Oil and Lubricants
Engine Oil Viscosity Diagram
Operating Materials
Service Data
Tightening Torque
Electrics
Removing and Installing Headlamp
Removing and Installing Headlight
Removing Side Section Instrument Carrier
Removing the Speedometer
Removing the Instrument Carrier
Removing the Headlight
Installing the Headlight
Installing the Instrument Carrier
Installing the Speedometer
Removing and Installing the Headlight
Installing Flashing Turn Indicator with Holder
Installing the Windscreen
Removing the Revolution Counter
Removing the Ignition Switch
Installing the Ignition Switch
Adjusting Headlamp
Adjusting Headlamp with Beam Adjuster
Removing and Installing Turn Signals
Removing and Installing Rear Light
Removing and Installing Speedometer
Removal Display Panel with Ignition Lock
Disassembling and Assembling, Installing Display Panel
Removing and Installing Handlebar Controls
Testing Operation of Alternator, Regulator and Diode Plate
Quick Test of Alternator and Regulator
Removing and Installing Battery
Removing and Installing Fuse Box
Removing, Testing and Installing Relays
Testing Operation of Turn Signal Relay
Testing Operation of Starter Relay
Testing Diode of Starter Relay
Removing and Installing Regulator
Removing and Installing Ignition Control Unit
Removing, Testing and Installing Ignition Coil
Removing, Testing and Installing Diode Plate
Removing, Installing Ignition Trigger
Replacing Carbon Brushes
Removing, Testing, Disassembling and Assembling Alternator
Testing Alternator
Testing Starter
Disassembling Stator
Assembling Stator
Installing Alternator
Removing Starter
Disassembling Starter
Removing and Installing Switch for Idle Display
Removing and Installing Oil Pressure Switch
Assembling Starter
Installing Starter
Removing and Installing Rear Stop Light Switch
Removing and Installing Front Stop Light Switch
Removing and Installing Clutch Switch
Removing and Installing Horn
Removing and Installing Chassis Cable Harness Section
Removing and Installing Rear Cable Harness Section
Troubleshooting
Brake System
Removing Front Wheel Brake
Removing Brake Caliper
Removing Front Wheel
Removing Brake Disc
Disassembling Brake Caliper GS
Assembling Brake Caliper
Removing and Installing Front Brake Pads
Stripping down R 100R Brake Caliper
Assembling R 100R Brake Caliper
Removing Brake Line
Removing Brake Fluid Reservoir and Master Brake Cylinder
Disassembling/Assembling Brake Fluid Reservoir/ Master Brake Cylinder
Installing Front Wheel Brake
Installing Brake Disc
Installing Brake Caliper
Removing Rear Wheel Brake
Installing Brake Line
Removing Rear Wheel
Removing Brake Shoes
Removing Brake Lever
Installing Rear Wheel Brake
Removing Foot Brake Lever
Installing Brake Key and Brake Lever
Installing Brake Shoes
Adjusting Foot Brake Lever Play
Suspension
Replacing Wheel Bearing
Removing Handlebars
Disassembling and Assembling Grip Units
Disassembling Right Grip Unit
Assembling Right Grip Unit
Disassembling Left Grip Unit
Assembling Left Grip Unit
Removing and Installing, Disassembling and Assembling Telescopic Fork
Stripping down Telescopic Fork
Measuring Telescopic Fork Alignment
Examining Stanchions
Examining Bottom Fork Bridge
Examine Parallelisms of the Stancions
Assembling Telescopic Fork
Assembling Stanchions
Removing and Installing Head Bearing
Removing and Installing Bottom Taper Roller Bearing
Examining Front Frame Section
Installing Telescopic Fork
Installing Handlebars
Installing Front Wheel
Measuring Track Alignment
Removing and Installing Spokes
Examining Rims for Runout, Centering
Static Wheel Balancing
Centering Lateral Runout
Removing, Disassembling and Assembling Rear Spring Strut
Installing the Input Bevel Pinion
Installing Crown Wheel
Adjusting Tooth Backlash
Checking Tooth Contact Pattern
Installing the Housing Cover
Shimming the Housing Cover
Removing and Installing Taper Roller Bearings
Installing Rear Wheel Drive
Installing Spring Strut
Frame Attachments
Installing Rear Wheel
Removing and Installing Rear Mudguard
Removing Rear Frame Section
Removing and Installing Side Stand
Removing and Installing Cylinder Guard
Disassembling Rear Frame Section
Removing and Installing Kickstand
Removing and Disassembling Foot Rests
Removing and Installing Air Filter Box
Installing Foot Rests
Removing Air Filter Box
Exhaust System
Removing and Installing Battery Mount
Removing and Installing Steering Lock
Removing and Installing Exhaust System
Removing Front Silencer and Exhaust Manifold
Installing Front Silencer and Exhaust Manifold
Installing Main Silencer
Gearbox
Removing Transmission
Disassembling Transmission
Removing and Installing Kick Starter
Removing Bearing Block for Shift Discs
Disassembling Bearing Block
Assembling Bearing Block
Removing and Disassembling Input Shaft
Assembling Input Shaft
Removing Output and Intermediate Shafts
Disassembling Output Shaft
Assembling Output Shaft
Replacing Radial Seal for Input Shaft
Replacing Roller Bearing of Input Shaft
Assembling Transmission
Calculating Thickness of Spacer Ring for End Play
Installing Transmission
Troubleshooting Transmission
Disassembling and Assembling Gear Shift Linkage
Installing Shift Lever
Clutch
Removing and Installing Clutch
Engine
Fuel Preparation
Removing and Disassembling Fuel Tap
Removing and Installing Bowden Cable for Cold Start Device
Removing and Installing Bowden Cables for Throttle Control
Removing Carburetor
Disassembling Carburetor
Removing Nozzle Set
Assembling Carburetor
Removing Shed Fuel System
Troubleshooting Shed-System
System Diagram of Shed Fuel System
Removing Engine
Disassembling Engine
Disassembling Cylinder Head
Checking Valve Guide for Wear
Reaming out Valve Guide
Replacing Valve Guides
Installing Valves
Removing Cylinder
Removing Conrod
Examining and Repairing Conrod
Examining Conrod for Parallelism and Twisting
Removing Oil Pump
Assembling Oil Pump
Replacing Radial Seal for Crank Shaft Seal
Removing Chain Box Cover
Replacing Radial Seal for Crankshaft Seal
Removing Camshafts
Examining Camshaft
Removing Crank Shaft
Determining Crankshaft Bearing Play
Removing Crankshaft Bearing
Removing Oil Sump and Intake Bell
Removing and Installing Bent Cover
Removing and Installing Bypass Valve
Assembling Engine
Installing Crank Shaft Bearing Bush in Engine Housing
Installing New Crankshaft Bearing Bush in Bearing Cover
Examining Conrod Bearing Play
Installing Crankshaft
Installing Camshaft
Attaching Chain Box Cover
Installing Oil Pump
Installing Piston
Installing Cylinder
Attaching Cylinder Head
Installing Engine
Installing Intake Bell and Oil Sump
Removing and Disassembling Oil Cooler
Troubleshooting Engine
Insufficient Compression Pressure
Engine Does Not Start Clearly or Not at All
Engine Pings
Technical Data
Engine Does Not Accelerate Properly
Engine Curs out
Engine Oil Vicosity Diagram

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R 100 r

BMW R 80 GS Repair Manual

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