BMW Motorrad R 100 PD Manuals

Manuals and User Guides for BMW Motorrad R 100 PD. We have 1 BMW Motorrad R 100 PD manual available for free PDF download: Repair Manual

BMW Motorrad R 100 PD Repair Manual (169 pages)

Brand: BMW Motorrad | Category: Motorcycle | Size: 10 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
Delivery Inspection
8
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 for Leaks on
9
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
Bright
14
Renewing Air Filter
15
Cleaning Fuel Cocks
15
Electrode Gap
15
Checking Spark Plugs and Electrode Gap
15
Cleaning Carburetors Float Housing
16
Checking/Adjusting Clutch Play
16
Checking/Adjusting Firing Point
16
Synchronising Carburetors Adjusting Cables
17
Setting Firing Point
17
Synchronising Carburetors Without CO Measurement
18
Synchronising Carburetors with CO Measurement
18
Final Adjustment of the Throttle Cables
18
Changing Oil and Oil Filter in Engine
19
Changing Oil in Transmission
19
Changing Oil Filter
19
Pouring in Engine Oil
19
Changing Transmission Oil in Rear Wheel Drive
20
Changing Oil in Telescopic Fork
20
Checking Front Brake Pad for Wear/Renewing
21
Renewing Brake Pads GS
21
Installing Brake Pads GS
21
Checking Brake Discs
22
Checking/Topping up Brake Fluid Level
22
Removing/Fitting Front Brake Pads
22
Checking Thickness of Brake Discs
22
Changing Brake Fluid
23
Bleeding Front Wheel Brake System
23
Bleeding Front Wheel Brake System with Bleeder
23
Checking Rear Barke Pads for Wear/Renewing Brake Shoe
24
Bleeding Front Wheel Brake Using Handbrake Lever
24
Checking Rear Brake Pads for Wear
24
Renewing Rear Brake Shoe
24
Checking/Adjusting Foot Brake Lever Play
25
Checking Rear Wheel for Tilt Play
25
Checking Front Wheel Bearing
25
Adjusting Foot Brake Lever Play
25
Checking/Adjusting Steering Bearing in 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 and Service Data for Maintenanec
28
Engine Oil Viscosity Diagram
30
Operating Materials
31
Lubricants
31
Sealants
31
Service Data
31
Electrics
32
Removing and Installing Headlamp
35
Removing and Installing Headlight
35
Removing Side Section of 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
Installing Flashing Turn Indicator with Holder
38
Installing the Windscreen
38
Removing the Windscreen
38
Installing the Ignition Switch
40
Installing the Revolution Counter
40
Tachometer
40
Adjusting Headlamp
41
Adjusting Headlamp Without Beam Adjuster
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
Testing Regulator
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
Removing and Installing Regulator
47
Removing/Installing Ignition Control Unit
47
Removing, Testing and Installing Ignition Coil
47
Removing, Testing and Installing Diode Plate
48
Removing and Installing Ignition Trigger
48
Replacing Carbon Brushes
48
Removing Testing, Disassembling and Assembling Alternator
49
Testing Starter
50
Disassembling Stator
50
Assembling Stator
50
Testing with Voltmeter
50
Removing, Disassembling, Assembling and Installing Starter
51
Removing and Installing Switch for Idle Display
52
Assembling Starter
52
Installing Starter
52
Removing and Installing Oil Pressure Switch
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 GS
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
Installing Front Wheel Brake
65
Installing Brake Claiper
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
Installing Foot Brake Lever
68
Installing Brake Key and Brake Lever
68
Installing Brake Shoes
68
Suspension
70
Replacing Wheel Bearings
73
Installing Wheel Bearings
73
Removing Handlebars
74
Disassembling and Assembling Grip Units
74
Disassembling Left Grip Unit
75
Assembling Left Grip Unit
75
Removing Telescopic Fork
76
Disassembling Telescopic Fork GS
77
Removing and Installing Shaft Seal and Sliding Bush in Sliding Tube
78
Stripping down Telescopic Fork
79
Stripping down the Fixed Tube
79
Measuring Telescopic Fork Alignment
80
Examining Stanchions
80
Examining Bottom Fork Bridge
80
Examine Parallelisms of the Stanchions
80
Assembling Telescopic Fork GS
81
Assembling Telescopic Fork R 100 R
81
Assembling Stanchions
82
Removing and Installing ST Head Bearing
83
Removing and Installing Bottom Taper Roller Bearing
83
Examining Front Frame Section
84
Installing Telescopic Fork
85
Installing Handlebars
86
Installing Headlight and Instruments
86
Installing Front Wheel
87
Measuring Track Alignment
87
Removing and Installing Spokes
89
Examining Rims for Runout Centering
89
Front Wheel Rim
89
Rear Wheel Rim
89
Static Wheel Balancing
90
Centering Lateral Runout
90
Removing, Disassembling and Assembling Rear Spring Strut
91
Stripping down Input Bevel Pinion
93
Removing the Needle Roller Bearing
93
Installing the Needle Roller Bearing
93
Installing the Input Bevel Pinion
94
Assembling the Input Bevel Pinion
94
Installing Crown Wheel
95
Shimming the 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 Rear Mudguard
101
Removing and Installing Side Stand, GS
102
Removing and Installing Cylinder Guard
102
Disassembling Rear Frame Section
102
Removing and Installing Kickstand
103
Removing, Disassembling and Assembling Installing 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 Main Silencer
107
Removing Main Silencer GS
107
Removing Front Silencer and Exhaust Manifold
108
Installing Front Silencer and Exhaust Manifold
108
Installing Main Silencer GS
108
Installing Main Silencer R100R
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
Assemlbing Input Shaft
115
Removing Output and Intermediate Shafts
116
Disassembling Output Shaft
117
Assembling Output Shaft
117
Replacing Roller Bearing of Input Shaft
117
Replacing Radial Seal for Input Shaft
117
Assembling Transmission
118
Calculating Thickness of Spacer Ring for End Play
118
Example of Calculation
118
Installing Transmission
120
Troubleshooting Transmission
121
Disassembling and Assembling Gear Shaft 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
Removing Engine
134
Disassembling Engine
135
Removing Cylinder Head
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 Piston and Cylinder
139
Examining and Repairing Conrod
140
Examining Conrd for Parallelism and Twisting
141
Removing Oil Pump
142
Examining Oil Pump
142
Assembling Oil Pump
142
Replacing Radial Seal for Crank Shaft Seal
142
Removing Chain Box Cover
143
Installing Seal
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 Belt Cover
146
Removing and Installing Bypass Valve
146
Assembling Engine
147
Installing New Crankshaft Bearing Bush in Bearing Cover
147
Examining Conrdo 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
Poor Performance
154
Engine Pings
154
Technical Data
155
Engine Does Not Accelerate Properly
155
Engine Cuts out - High Fuel Consumption
155

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BMW Motorrad R 100 PD Repair Manual (169 pages)

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