BMW R 1100 S 1999 Repair Manual
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BMW R 1100 S 1999 Repair Manual

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Repair Manual
R 1100 S
BMW AG Motorcycle Division
After Sales

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Summary of Contents for BMW R 1100 S 1999

  • Page 1 Repair Manual R 1100 S BMW AG Motorcycle Division After Sales...
  • Page 2 Published by: © BMW AG Motorcycle Division After Sales UX-VS-2 All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission. Errors and omissions excepted; subject to technical amendment. Produced in Germany 06/99...
  • Page 3 All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification. The repair manual is structured in the logical sequence of the work to be performed: Removal, Dis- assembly, Repair, Assembly, Installation.
  • Page 5 Contents Group / Chapter 00 Maintenance and general instructions 11 Engine 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...
  • Page 6 Group / Chapter 34 Brakes 36 Wheels and tyres 46 Frame 51 Equipment 52 Seat 61 General electrical equipment 62 Instruments 63 Lights...
  • Page 7 Licence plate No. Order No. Mechanic’s signature Read out the fault memory with the BMW MoDiTeC unit Change the oil while at regular operating temperature and renew the oil filter element if motorcycle is used only for short journeys or at outside temperatures under 0°C, every 3 months,...

  • Page 8: Engine

    BMW AG Motorcycle Division Pre-delivery check R 1100 S Customer Licence plate No. Pre-delivery check Order No. Mechanic’s signature Checking the shipping crate for damage Motorcycle: – unpack – attach items supplied loose – inspect for damage – check that delivery is complete:...

  • Page 9: Tightening Torques And Table Of Consumables

    00 Maintenance and general instructions Tightening torques and Table of consumables Pre-delivery check Maintenance Contents Page Tightening torques ........................5 Table of consumables ......................11 00.1...

  • Page 10: Table Of Contents

    Pre-delivery check Contents - Pre-delivery check Page Pre-delivery check ........................13 General view of crated motorcycle ..................13 Checking the crate for damage ..................14 In case of damage in Germany ....................14 In case of damage in importer markets ................14 Unpacking the motorcycle ....................14 Installing remaining items on motorcycle...
  • Page 11 Maintenance Contents - Maintenance Page Maintenance ..........................20 Key to maintenance intervals ....................20 Reading out MoDiTeC fault memory ................20 (Inspections I, II, III and IV) Changing engine oil, replacing oil filter element ............20 (Inspections I, II, III and IV) Changing oil in gearbox ......................21 (Inspections III and IV) or every 2 years at the latest...
  • Page 12 Contents - Maintenance Page Changing brake fluid and bleeding brake system ...........30 Change the brake fluid annually (Inspection IV) [ABS Inspections II and III] Bleeding front brake circuit/changing brake fluid ............30 Additional information for [ABS] Bleeding rear brake circuit/changing brake fluid ............32 Checking clutch fluid level ....................33...
  • Page 13 Tightening torques Model R 1100 S Connection 11 Engine Cylinder head Tightening sequence: 1. Tighten cylinder head nuts (oiled) in diagonally opposite sequence 1.1 Tighten all nuts to closing torque 1.2 Tighten all nuts to wrench angle 90° 1.3 Tighten all nuts to wrench angle 90°...
  • Page 14 Model R 1100 S Connection 11 Engine Oil pump Mesh filter basket to engine block Oil pump cover Pressure relief valve Oil pressure switch Oil cooler Oil cooler pipe to engine block Cooling oil line – banjo screw with oil vent valve Oil cooler to fairing bracket Oil cooler return line to engine block Oil cooler connection to crankcase...

  • Page 15: Fuel Preparation And Control

    Model R 1100 S Connection 12 Engine electrics Starter motor to engine Starter cover to gearbox housing Alternator to cover mount Tensioning and retaining link to alternator Spacer to alternator Belt pulley to alternator Series generator 560 W Do not release Option 700 W Belt pulley to crankshaft Poly-V belt preload...
  • Page 16 Model R 1100 S Connection 23 Transmission Oil drain plug Oil filler plug Gearbox to engine block Foot shift lever to footrest plate Selector lever to selector shaft Gearbox cover to gearbox housing 31 Front fork Quick-release axle clamp screws Clamp, fork fixed tube to fork bridge Slider tube bridge to slider tube 25 (clean thread + Loctite 243)

  • Page 17: M6 Screw

    Model R 1100 S Connection 33 Rear wheel drive Reaction link to rear wheel drive/main frame Load approx. 85 kg (187 lbs) onto motorcycle and tighten loose reaction link Spring strut to main frame Spring strut to rear swinging arm 34 Brakes Brake caliper to fork slider tube Brake caliper to rear wheel drive...
  • Page 18 Model R 1100 S Connection 46 Frame Main frame to engine M 10 screw, top right Initial tightening 13 Final tightening 42 M 10 screw, top left M 10 bolts at top (struts to engine) M 10 screw, long, frame/gearbox M 12 screw, bottom M 8 screw, long, bottom Rear frame to main frame...

  • Page 19: Table Of Consumables

    83 19 9 407 855 500 ml spray housings Crack testing agent for aluminium Developer MR 70 81 22 9 407 495 500 ml spray housings Installation aid BMW cooling spray Cooling spray 83 19 9 407 762 300 ml spray 00.11...
  • Page 20 00.12...

  • Page 21: Pre-Delivery Check

    Pre-delivery check General view of crated motorcycle 00.13...

  • Page 22: Checking The Crate For Damage

    Tel. +49 89 14327 632 Check for defects. • Fax. +49 89 14327 709 Send an “Urgent notification” to • Immediately notify the freight carrier (e.g. freight BMW AG, Sparte Motorrad, UX-VS-1 forwarder). Fax No. +49 89 382 33220 • Rectify the defect. •...

  • Page 23: Filling And Charging The Battery

    S000020 Filling and charging the battery Filling and charging the battery Disengaging and raising the fuel tank Warning: • Remove seat. Battery acid is severely caustic. • Remove right and left side trim panels. Protect your eyes, face, hands and clothing and the paintwork.

  • Page 24: Checking Engine Oil Level When Cold, Adding Oil If Necessary

    • Check the oil level with the motorcycle upright: if necessary, use stand, BMW No. 00 1 560, to Tightening torque: keep the motorcycle in the upright position. Fuel tank to rear frame ......... 10 Nm Caution: Never top up the engine-oil level past the MAX mark.

  • Page 25: Checking Clutch Fluid Level

    • Motorcycle upright; if necessary, use stand, Rear brake BMW No. 00 1 560, to hold the motorcycle up- right. • • Turn the handlebar fully to the right. Motorcycle upright; if necessary, use stand, BMW No.

  • Page 26: Checking Headlight Beam Angle, Adjusting If Necessary

    Checking headlight beam angle, Checking tightness of rear wheel adjusting if necessary studs Tightening torque: Rear wheel studs ........105 Nm Checking tyre pressures • Check/correct tyre pressures. Tyre pressures: Solo ........front 2.2 bar (31.3 psi) ..........rear 2.5 bar (35.6 psi) Two-up ........

  • Page 27: Final Inspection And Function Check

    Final inspection and function check Handing over the motorcycle • Clutch This is the ideal opportunity to familiarise the cus- • Check gear shift action. tomer with the motorcycle in order to ensure the • Handbrake and foot brake customer’s satisfaction and safety. •...

  • Page 28: Maintenance

    Remove oil drain plug and drain off oil. • Fit new seal and screw in drain plug. • Use oil filter wrench, BMW No. 11 4 650, to re- move the oil filter. • Coat sealing ring on new oil filter element with oil and install filter.

  • Page 29: Changing Oil In Gearbox

    S000120 • Remove oil filler plug (1). • Use socket-head key, BMW No. 23 4 690 and torque wrench, to remove oil drain plug (2) and drain the oil into a suitable container. • Clean the magnet in the oil drain plug.

  • Page 30: Changing Oil In Rear Wheel Drive; Cleaning Inductive Signal Transmitter At Rear Wheel

    Changing oil in rear wheel drive; cleaning inductive signal transmitter at rear wheel (Inspections I, III and IV) Every 40 000 km (24 000 miles) or every 2 years at the latest • Change the oil with the rear wheel drive at oper- ating temperature.

  • Page 31: Replacing Fuel Filter

    • Disengage the fuel tank. • Seal the fuel feed and return lines with hose clips, BMW No. 13 3 010, and disconnect. • Pull the plug connector off the fuel pump unit. • Remove the fuel tank.
  • Page 32 Note correct direction of flow through fuel filter. Make sure that breather lines are correctly routed. • Secure non-reusable hose clips with pliers, BMW No. 13 1 500. Caution: Make sure that O-ring (2) is in perfect condition. Tightening torque: Fuel pump unit ..........

  • Page 33: Checking Battery Fluid Level And Topping Up If Necessary; Cleaning And Greasing The Battery Posts

    S000020 Checking battery fluid level and Replacing intake air filter element topping up if necessary; cleaning and (Inspection III) greasing the battery posts In very dirty and dusty operating conditions, replace every 10 000 km (6 000 miles) or even (Inspections III and IV) more frequently if necessary •...

  • Page 34: Replacing Poly-V Belt

    Pull off spark plug caps with special puller, BMW No. 12 3 520. Poly-V belt tensioning procedure: • Use spark plug wrench, BMW No. 12 3 510, to 1. Hand-tighten hex nut (1) on adjusting screw (2) remove the spark plugs. (do no use tools).

  • Page 35: Checking Brake Fluid Level

    Rear brake operation and freedom from leaks; • Motorcycle upright; if necessary, use stand, repairing/replacing if necessary BMW No. 00 1 560, to hold the motorcycle up- (Inspection III) right. • Checking brake system for leaks. Checking brake fluid level...

  • Page 36: Checking Brake Pads And Discs For Wear/Replacing

    Checking brake pads and discs for Checking brake disc wear wear/replacing (Inspections II and III) Checking front brake pad wear S000160 • Examine the brake discs carefully for cracks, damage, distortion, wear and score-marks. S000140 Brake disc wear limit: front:..........4.0 mm (0.16 in) •...

  • Page 37: Replacing Brake Pads, Front Brake

    Installation is the reverse of the removal proce- dure. • Before installing the brake caliper, force the pis- tons fully back with resetting tool, BMW No. 34 1 500. Tightening torque: Brake caliper to fork slider tube....40 Nm 00.29...

  • Page 38: Changing Brake Fluid And Bleeding Brake System

    ....See Additional information for [ABS] 34 1 500 S000190 S000261 • Use resetting tool, BMW No. 34 1 500, to force • the pistons of the right-hand brake caliper fully Wrap a cloth around the filler adapter in the right back.

  • Page 39: Additional Information For [Abs]

    Draw off brake fluid until it emerges clear and • Motorcycle upright; if necessary, use stand, free from air bubbles. • BMW No. 00 1 560, to hold the motorcycle up- Close the bleed screw. right. Tightening torque: Bleed screw in pressure modulator ....9 Nm S000071 •...

  • Page 40: Bleeding Rear Brake Circuit/Changing Brake Fluid

    [ABS] Begin by bleeding the pressure modula- tor. Brake fluid grade .........DOT 4 ....See Additional information for [ABS] • Use the auxiliary stand, BMW No. 00 1 560. Tightening torque: • Remove reservoir cover. Bleed screw in rear brake caliper ....6 Nm Brake caliper to rear wheel drive ....

  • Page 41: Checking Clutch Fluid Level

    If other devices are used, comply with their manu- facturers’ instructions. • Place the motorcycle on the auxiliary stand, BMW No. 00 1 560, and turn the handlebars fully to the right. S000051 • Remove reservoir cover with rubber diaphragm.

  • Page 42: Checking Tightness Of Rear Wheel Studs

    Checking tightness of rear wheel Caution: studs The motorcycle is not permitted on the road without the grubscrew in place and secure in the filler adapt- (Inspection I) • Check security of the rear wheel studs with a • Correct the fluid level. torque wrench.

  • Page 43: Greasing The Side Stand Pivot

    C000060 • • Check free movement of side stand and grease Remove spark plugs with the spark plug wrench, if necessary. BMW No. 12 3 510. • Grease pivot point (arrow). Lubricant: Caution: For side stand pivot..... Shell Retinax EP2 Do not bend electrodes –...

  • Page 44: Tightening Cylinder Heads

    Tightening cylinder heads Checking/adjusting valve clearances (Inspection I) (Inspections I, II and III) C000210 RS110980 • Remove cylinder head cover. • Check valve clearance with feeler gauge and, if Caution: necessary, correct with adjusting screw. Catch escaping oil. Adjust valve clearances with the engine cold (max.

  • Page 45: Checking Throttle-Cable Play

    Checking throttle cable for ease of Play of throttle cable: ..approx. 2 mm (0.08 in) movement, abrasion and kinks; • Connect hose of BMW Synchro to vacuum replacing if necessary adapter and connect cables to BMW MoDiTeC. Checking throttle-cable play •...

  • Page 46: Final Inspection With Road Safety And Functional Check

    Final inspection with road safety and functional check (Inspections I, II, III and IV) Road safety check • Check wheels and tyres. • Check/correct tyre pressures. • Wait at least 10 minutes after the trial run/road test before checking/correcting engine oil level. Tyre pressures: Solo ........
  • Page 47 11 Engine Contents Page Technical Data ..........................5 Cutaway drawing of engine Lubricating-oil circuit .......................11 Cooling-oil circuit ........................13 Removing engine ........................15 Disassembling engine ......................17 Removing cylinder head cover ....................18 Locking the engine at TDC .......................19 Firing TDC ............................19 Removing and installing chain tensioner ............................20 Work instructions, timing-chain tensioner ..................20...
  • Page 48 Contents Page Removing auxiliary shaft drive ....................33 Removing oil pump ........................34 Removing radial shaft seal from crankshaft with engine installed .....................35 Disassembling crankcase ......................36 Removing crankshaft, auxiliary shaft and timing chain tensioning and slide rails ...............38 Removing and installing oil intake strainers ..............39 Replacing oil level sight glass ....................39...
  • Page 49 Contents Page Adjusting valve clearances .......................55 Installing right cylinder head ....................56 Adjustment specification ........................56 Installing left cylinder head .......................57 Adjustment specification ........................57 Installing alternator mount cover ...................59 Installing magnetic gate/belt pulley ..................59 Timing the ignition ..........................60 Installing alternator ........................61 Installing engine ..........................62 11.3...
  • Page 50 11.4...
  • Page 51 Technical Data R 1100 S Engine, general Engine design Four-stroke flat twin, air-cooled with oil- cooled exhaust ports, installed longitudinal- ly, 4 valves per cylinder, two overhead cam- shafts, electronic fuel injection. Location of engine number Crankcase Cylinder bore mm (in) 99 (3.9) Stroke mm (in) 70.5 (2.78) Effective displacement...
  • Page 52 Technical Data R 1100 S Valves Included valve angle ° 41 Valve clearances with engine cold (max. 35 °C/95 °F) Inlet valve mm (in) 0.15 (0.059) Exhaust valve mm (in) 0.30 (0.012) Valve timing without valve clearance, 3 mm (0.12 in) valve lift Inlet opens 5°...

  • Page 53: Camshaft

    Technical Data R 1100 S Valve guide Valve guide Extl. dia. mm (in) 12.533...12.544 (0.4934...0.4939) Bore in cylinder head mm (in) 12.500...12.518 (0.4921...0.4928) Overlap mm (in) 0.015...0.044 (0.0006...0.0017) Repair stages Replacement valve guide Extl. dia. mm (in) 12.550...12.561 (0.4941...0.4945) Oversize valve guide Extl.
  • Page 54 Technical Data R 1100 S Bucket-type tappet Extl. dia. mm (in) 23.947...23.960 (0.9428...0.9433) Bore in cylinder head mm (in) 24.000...24.021 (0.9449...0.9457) Radial clearance mm (in) 0.040...0.074 (0.0016...0.0029) Wear limit mm (in) 0.18 (0.007) Auxiliary shaft Bore in crankcase front/back mm (in) 25.020...25.041 (0.9851...0.9859) Auxiliary shaft dia.
  • Page 55 Technical Data R 1100 S Connecting rod Big-end bore mm (in) 51.000...51.013 (2.0079...2.0084) Big end bearing dia. mm (in) 48.016...48.050 (1.8904...1.8918) Radial clearance mm (in) 0.025...0.075 (0.010...0.0030) Wear limit mm (in) 0.13 (0.005) Width of big end bearing eye mm (in) 21.883...21.935 (0.8616...0.8636) Conrod end float mm (in) 0.130...0.312 (0.0051...0.0123) Wear limit...
  • Page 56 Technical Data R 1100 S Piston rings 1st groove Piston ring asymmetric, convex oval Thickness mm (in) 1.170...1.190 (0.0461...0.0469) Wear limit mm (in) 1.1 (0.04) End gap mm (in) 0.1...0.3 (0.004...0.012) Wear limit mm (in) 0.8 (0.03) Side clearance mm (in) 0.030...0.070 (0.0012...0.0027) Wear limit mm (in) 0.15 (0.006) 2nd groove Micro-taper compression ring...

  • Page 57: Cutaway Drawing Of Engine

    Cutaway drawing of engine 11.11...

  • Page 58: Lubricating-Oil Circuit

    Lubricating-oil circuit 11.12...

  • Page 59: Cooling-Oil Circuit

    Cooling-oil circuit 11.13...
  • Page 60 11.14...

  • Page 61: Removing Engine

    34/Removing ABS unit S110010 • [ABS] Remove the pressure modulator. • • Secure stand, BMW No. 00 1 520, to motorcy- Remove the rear side panel on the right. • cle. Disconnect plug for rear wiring harness. • •...
  • Page 62 • • Use pliers, BMW No. 17 5 500, to release hose Remove front silencer. • clip securing breather hose to air filter box. Use a strap with ratchet latch to secure bottom • Remove air filter box. fork bridge to top fork bridge.

  • Page 63: Disassembling Engine

    00 0 630 RS110010 Disassembling engine • Secure engine mount, BMW No. 11 0 630, to the engine block. • Transfer engine to assembly frame. 11 4 650 RS110950 • Drain engine oil. • Remove the oil filter, using oil filter wrench, BMW No.

  • Page 64: Removing Cylinder Head Cover

    12 3 510 RS110020 Removing cylinder head cover • Remove spark plugs with the spark plug wrench, BMW No. 12 3 510. • Remove cylinder head cover. Caution: Catch escaping oil. 11.18...

  • Page 65: Locking The Engine At Tdc

    Lock the clutch housing with special tool, BMW No. 11 5 640. RS110461 Note: The engine can be locked at TDC by inserting locat- ing pin, BMW No. 11 2 650, through the hole in the clutch housing and the engine block. 11.19...

  • Page 66: Removing And Installing Chain Tensioner

    RS110060 Removing and installing chain tensioner Caution: Do not mix up the chain tensioner pistons. When in- stalling, fit a new seal. Work instructions, timing-chain tensioner Removing: • Remove timing chain tensioner, then remove camshaft sprocket from camshaft. Installing: • First install camshaft sprocket, then timing chain tensioner.

  • Page 67: Removing Valve Gear Holder

    M6 x 60 M6 x 30 M6 x 30 M6 x 30 S110110 Removing valve gear holder • Remove valve gear holder. • Secure rockers with a rubber band (2). Note: If no work is carried out on the valve gear holder, re- move it together with the cylinder head.

  • Page 68: Disassembling/Assembling Valve Gear Holder

    RS110080 Disassembling/assembling valve gear holder • Remove bearing cap. • Insert a suitable pin into the bore (arrow) of the rocker shaft, and turn the shaft back and forth to remove it from its bearing. • Remove pushrods. Caution: Do not mix up the rocker shafts and pushrods. 11.22...

  • Page 69: Camshaft Bearing Cap

    RS110090 • Remove camshaft bearing cap (1). • Remove camshaft and bearing (2). • Remove bucket-type tappets. Caution: Do not mix up the bucket-type tappets. • Assembly is the reverse of the disassembly pro- cedure. Caution: Note direction of installation (3) for camshaft bearing cap.

  • Page 70: Removing Cylinder Head

    M10 x 70 M6 x 30 M6 x 30 M6 x 30 RS110110 Removing cylinder head 11.24...

  • Page 71: Disassembling, Checking, Repairing And Reassembling Cylinder Head

    Do not scratch sealing face on cylinder head. Place the head on a clean, non-scratching surface. • Mount valve spring compressor, BMW No. 11 5 690, on cylinder head. • Compress the valve springs. • Gently tap valve head to release collets from spring retainer.

  • Page 72: Checking Valves For Wear

    Checking valves for wear • Clean combustion residue from valves. • Check valve dimensions..........see Technical Data Remachining valve seat RS110890 Caution: Width (B) and diameter (D) must always be main- tained if valve seat is machined..........see Technical Data Checking and repairing cylinder head •...

  • Page 73: Replacing Valve Guides

    Immediately before pressing in, the temperature • Drive out valve guides with 5 mm (0.20 in) dia. must be –40 °C (–40 °F). drift, BMW No. 11 5 674, from the combustion • chamber side. Place heated cylinder head flat on workbench or •...

  • Page 74: Installing Valve And Valve Stem Seal

    Shrink a short length of tube (arrow) on to the end of the valve stem. • Install the valve stem seal with a 5 mm (0.20 in) dia. drift, BMW No. 11 5 602. Caution: Remove the shrink-fit tube. •...

  • Page 75: Removing Cylinder

    RS110170 Removing cylinder • Remove guide rail bearing screws (1). • Remove cylinder retaining screws, and remove cylinder. Caution: When removing cylinder, make sure that the piston does not strike the engine block. Removing and disassembling piston • Remove both retaining rings from piston pin. •...

  • Page 76: Checking Pistons And Cylinders

    Checking pistons and cylinders Assembling pistons Reference temperature for measurements: ............20 °C (68 °F) S110170 RS110180 • Carefully fit piston rings to piston in the following • Measure cylinder bore with internal probe at sequence, using piston ring pliers: 20 mm (0.79 in) and 100 mm (3.94 in) from the 3rd groove - 3-S ring top in direction of piston pin, and again at a right...

  • Page 77: Removing And Installing Conrod

    Turn crankshaft to TDC position. • • Lock the clutch housing with special tool, Screw the big end bolts in by hand, then tighten BMW No. 11 5 640. them with a tightening angle indicator, • Remove conrods. BMW No. 11 2 500.

  • Page 78: Removing And Installing Alternator Mount Cover With Engine Installed

    It is not necessary to remove magnetic gate (2) when Drive in the new radial shaft seal with drift and removing the alternator mount cover as a unit. sliding sleeve, BMW No. 11 5 680. • Remove alternator mount cover (3).

  • Page 79: Removing Auxiliary Shaft Drive

    Remove chain tensioning rail (3). • Remove chain guide rail (4). • Lock the clutch housing with special tool, BMW No. 11 5 640. • Remove chain sprocket retaining bolt (5). • Remove sprocket (6) and timing chain (7). •...

  • Page 80: Removing Oil Pump

    M6 x 45 M6 x 50 M6 x 45 M6 x 45 RS110410 M6 x 50 Removing oil pump • Remove oil pump cover (1). • Remove complete oil pump (2) together with cooling oil pipe (3), and disassemble. Caution: Check installed positions of parts which have al- ready been run together.

  • Page 81: Removing Radial Shaft Seal From Crankshaft With Engine Installed

    Using awl, BMW No. 00 8 583, carefully punch a hole in the shaft sealing ring. • Screw the pull rod, BMW No. 00 8 581, into the hole and use impact weight, BMW No. 00 8 582, S110040 to remove the shaft sealing ring.

  • Page 82: Disassembling Crankcase

    RS110261 Disassembling crankcase • Turn engine on to its side. • Remove screws on right side. 11.36...
  • Page 83 RS110260 • Turn engine on to its side. • Remove screws on left side. • Remove upper section of crankcase. 11.37...

  • Page 84: Removing Crankshaft, Auxiliary Shaft And Timing Chain Tensioning And Slide Rails

    S110050 Removing crankshaft, auxiliary shaft and timing chain tensioning and slide rails 11.38...

  • Page 85: Removing And Installing Oil Intake Strainers

    • Coat the sealing face of the new oil level sight glass with engine oil and drive it in with drift, BMW No. 00 5 550. Removing and installing oil thermostat S110070 •...

  • Page 86: Measuring Crankshaft Bearing Play

    RS110310 Measuring crankshaft bearing play Measuring radial bearing play • Measure main bearing journal with an external micrometer in two planes, A and B, at right an- gles. • Enter measured values on record sheet..........See Technical Data Caution: The crankshaft can only be reground in grinding stage 0;...

  • Page 87: Installing Main Bearings

    00 2 510 RS110910 • Screw measuring device, BMW No. 00 2 500, with dial gauge, BMW No. 00 2 510, into tapped hole for alternator carrier cover. • Move crankshaft forwards and backwards and read axial play from dial gauge.

  • Page 88: Measuring Big End Bearing Play

    ........... See Technical Data • Install bearing shells and assemble conrods. • Using tightening angle indicator, BMW No. 11 2 210, tighten the big end bolts. Tightening torque: Big end bolts oiled Joint torque..........20 Nm Wrench angle ............ 80°...

  • Page 89: Assembling Engine

    Clamp crankshaft in a vise with protective jaws. • Oil the big end bolts, screw them in by hand and tighten with tightening angle indicator, BMW No. 11 2 500. Caution: Oil the bearings. Make sure that conrods and bearing shells are re- installed in their original positions.

  • Page 90: Installing Crankshaft

    S110080 Installing crankshaft Installing auxiliary shaft/timing chains • When installing the auxiliary shaft, make sure that Caution: the bore in the auxiliary shaft (2) facing the crank- Oil the bearings. shaft is in line with the crankcase mating face. Caution: Installing timing chain tensioning and Timing chains (3) must mesh fully with auxiliary shaft sprockets.

  • Page 91: Assembling Engine Block

    RS110920 Assembling engine block • Clean and degrease sealing faces (arrow) and coat with 3-Bond 1209. • Secure the timing chain with rubber band (1) to the timing chain tensioner and slide rail. 11.45...
  • Page 92 RS110391 • Bolt the crankcase sections together. Tightening torque/tightening order: 1. M 10 screw (oiled) Initial torque ..25 Nm Wrench angle ..... 90° 2. M 8 screw (oiled) ........22 Nm 3. M 6 screw ..........9 Nm 11.46...
  • Page 93 11 5 702 11 5 703 11 5 703 11 5 703 11 5 702 11 5 703 11 5 703 11 5 701 00 5 500 00 5 500 11 5 661 11 5 661 11 5 662 11 5 662 00 5 500 11 5 661 11.47...

  • Page 94: Installing Radial Shaft Seals On Crankshaft

    Remove assembly sleeve (3). • Mount sleeve complete with radial shaft seal on crankshaft (4). • Use drift, BMW No. 11 5 701, together with the sleeve (5) to drive the radial shaft seal onto the crankshaft. • Remove sleeve (6).

  • Page 95: Installing Clutch Housing

    • Install clutch housing with mark (1) aligned with crankshaft mark (2). • Lock the clutch housing with special tool, BMW No. 11 5 640. • Insert all screws by hand and tighten down. Tightening torque: Clutch housing to crankshaft (screw threads oiled) ........

  • Page 96: Installing Oil Pump

    M6 x 45 M6 x 50 M6 x 45 M6 x 45 M6 x 50 RS110411 Installing oil pump Caution: Oil the friction faces. • Install outer rotor (1) of oil pump in pump hous- ing. • Install oil pump housing with cooling oil pipe (2). Caution: O-ring (3) must be in perfect condition.

  • Page 97: Installing Auxiliary Shaft Drive

    M 6 screw ............ 10 Nm Banjo bolt for cooling oil line with oil vent valve ......... 25 Nm • Lock the clutch housing with special tool, BMW No. 11 5 640. • Install chain sprocket (1). Tightening torque: M 6 screw ............ 10 Nm •...

  • Page 98: Installing Piston

    RS110430 Installing piston • Turn oil scraper ring so that gap (arrow) is at top. • Install piston rings with gaps offset by 120°. Production locating point X = install on exhaust side. Caution: Make sure that retaining rings are properly seated on piston pin.

  • Page 99: Installing Cylinder

    • Oil the cylinder wall. • Compress the piston rings with a clamping strap, BMW No. 11 2 900. • Install the cylinder and at the same time pass the timing chain and the tensioner and guide rails through the timing case cavity.
  • Page 100 11.54...
  • Page 101 GS510040 Removing and installing lock barrel for fuel tank filler cap Note: Make sure that screws do not fall into fuel tank: cov- er fuel tank filler neck with cloth. • Open cap and remove lower part of cap (1). •...
  • Page 102 52 Seat Contents Page Removing and installing seat ....................3 52.1...
  • Page 103 52.2...
  • Page 104 S520010 Removing and installing seat 52.3...
  • Page 105 52.4...
  • Page 106 61 General electrical equipment Contents Page Technical Data ..........................3 Relay positions (central electrical equipment box) ...........5 Fuse assignments ..........................5 Left fuse box ............................5 Right fuse box .............................5 Frame wiring harness ........................6 Wiring harness View from left ............................7 Wiring harness View from right ..........................11 61.1...
  • Page 107 61.2...

  • Page 108: Technical Data

    Technical Data R 1100 S Battery Option: 61.3...
  • Page 109 61.4...

  • Page 110: Relay Positions (Central Electrical Equipment Box)

    S610010 Relay positions (central electrical Fuse assignments equipment box) Left fuse box (No. 1 on left, looking forwards) 1. ABS warning relay 2. Relief relay 1. Instrument panel, controller for fuel 3. Horn relay warning lamp or indicator damping, 4. Indicator damping brake light ..........

  • Page 111: Frame Wiring Harness

    Frame wiring harness Caution: Use (yellow) galvanized screws for the ground (earth) connection to the engine. Screws with unsuitable corrosion proofing can cause the electrical resistance to rise as high as Ω Run wiring without kinking and avoid risk of abra- sion.

  • Page 112: Wiring Harness View From Left

    Wiring harness View from left S619010 61.7...
  • Page 113 S619011 61.8...
  • Page 114 S619012 61.9...
  • Page 115 S619013 61.10...

  • Page 116: Wiring Harness View From Right

    Wiring harness View from right S619020 61.11...
  • Page 117 S619021 61.12...
  • Page 118 S619022 61.13...
  • Page 119 S619023 61.14...
  • Page 120 62 Instruments Contents Page Technical Data ..........................3 Removing and installing instrument panel ..............5 Disassembling and assembling instrument panel .............5 62.1...
  • Page 121 62.2...
  • Page 122 Technical Data R 1100 S Instrument cluster Instrument lighting T6.5 12 V 3 W Telltale and warning lights T6.5 12 V 1.7 W 62.3...
  • Page 123 62.4...
  • Page 124 S620010 Removing and installing instrument panel • Remove side panels. • Remove mirrors. • Remove fairing. • Open electrics box on right. • Disconnect plug of instrument panel. • Remove fuses from instrument panel. • Remove instrument panel. • Installation is the reverse of the removal proce- dure.
  • Page 125 62.6...
  • Page 126 63 Lights Contents Page Technical Data ..........................3 Removing and installing headlight ..................5 Adjusting headlight ........................5 63.1...
  • Page 127 63.2...
  • Page 128 Technical Data R 1100 S Headlight Twin halogen headlights Low (dipped) beam headlight: Projection type High (main) beam headlight: Free-form type Bulbs Low (dipped) beam headlight H 1 halogen bulb, 12 V 55 W High (main) beam headlight H 7 halogen bulb, 12 V 55 W Parking light 12 V/5 W Standard designation W 5 W...
  • Page 129 63.4...
  • Page 130 S630010 Removing and installing headlight Caution: Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. Do not touch inner surface of reflector or bulbs with bare hands. • Remove side panels. • Remove mirrors. • Remove the windscreen. •...
  • Page 131 63.6...

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