BMW R 1100 RS Manuals

Manuals and User Guides for BMW R 1100 RS. We have 1 BMW R 1100 RS manual available for free PDF download: Repair Manual

BMW R 1100 RS Repair Manual

BMW R 1100 RS Repair Manual (464 pages)

BMW Motorcycle  
Brand: BMW | Category: Motorcycle | Size: 23.58 MB
Table of contents
Service Data8................................................................................................................................................................
Maintenance And General Instructions9................................................................................................................................................................
Table Of Contents10................................................................................................................................................................
Tightening Torques R 1100 Rs / R 1100 Rt11................................................................................................................................................................
Tightening Torques R 850/1100 Gs Und R 850/1100 R20................................................................................................................................................................
Operating Materials29................................................................................................................................................................
Key To Maintenance Intervals30................................................................................................................................................................
Change Engine Oil, Renew Oil Filter Element30................................................................................................................................................................
Change The Oil In The Gearbox And Rear Wheel Drive31................................................................................................................................................................
Changing Oil In Rear Wheel Drive31................................................................................................................................................................
Changing Oil In Gearbox31................................................................................................................................................................
Checking Battery Acid Level/topping Up If Necessary, Cleaning/greasing32................................................................................................................................................................
Renewing Air Cleaner32................................................................................................................................................................
Battery Posts32................................................................................................................................................................
Renewing Fuel Filter33................................................................................................................................................................
Checking/renewing Spark Plugs37................................................................................................................................................................
Taking Up Slack At Cylinder Heads37................................................................................................................................................................
Checking/adjusting Valve Operating Clearances38................................................................................................................................................................
Adjusting Poly-v Belt39................................................................................................................................................................
Renewing Poly-v Belt39................................................................................................................................................................
Checking Brake Pads And Discs For Wear/renewing40................................................................................................................................................................
Renewing Brake Pads – Front Brake40................................................................................................................................................................
Checking Brake Pads For Wear40................................................................................................................................................................
Rs] Renewing Brake Pads - Rear Brake41................................................................................................................................................................
Checking Brake Discs For Wear41................................................................................................................................................................
Checking Brake Fluid Level/topping Up41................................................................................................................................................................
Gs/r/rt] Renewing Brake Pads - Rear Brake41................................................................................................................................................................
Bleeding Front Brake Circuit/renewing Fluid42................................................................................................................................................................
Bleeding Rear Brake Circuit/renewing Brake Fluid42................................................................................................................................................................
Grease The Centre Stand [rs], Side Stand And Clutch Cable Nipple43................................................................................................................................................................
Rs] Cleaning And Greasing The Windshield Adjusting Shaft43................................................................................................................................................................
Version With Plain Bearing Only43................................................................................................................................................................
Checking Tightness Of Rear Wheel Studs45................................................................................................................................................................
Rs] Check Tightness Of Screws At Adjustable Handlebar45................................................................................................................................................................
Checking Swinging Arm Bearings, Adjusting If Necessary45................................................................................................................................................................
R] Check Steering Damper45................................................................................................................................................................
Taking Up Slack On Hose Clips At Intake Stub Pipen45................................................................................................................................................................
Checking Throttle Synchronisation/co Emission Value46................................................................................................................................................................
Final Inspection With Road Safety And Functional Check50................................................................................................................................................................
Motor51................................................................................................................................................................
Removing Engine91................................................................................................................................................................
Removing Cylinder Head Cover105................................................................................................................................................................
Removing Valve Gear Holder108................................................................................................................................................................
Dismantling/reassembling Valve Gear Holder109................................................................................................................................................................
Removing Cylinder Head111................................................................................................................................................................
Dismantling, Checking, Repairing And Re-assembling Cylinder Head112................................................................................................................................................................
Removing Cylinder Barrel116................................................................................................................................................................
Removing/dismantling Piston116................................................................................................................................................................
Checking Pistons And Cylinders117................................................................................................................................................................
Assemble Pistons117................................................................................................................................................................
Removing/installing Conrod118................................................................................................................................................................
Removing And Installing Alternator Cover With Engine Installed119................................................................................................................................................................
Removing Alternator Mount Cover119................................................................................................................................................................
Renewing Radial Shaft Seal In Alternator Mount Cover120................................................................................................................................................................
Renewing Radial Shaft Seal For Rotary Breather120................................................................................................................................................................
Removing Auxiliary-shaft Drive121................................................................................................................................................................
Removing Oil Pump122................................................................................................................................................................
Oil Temperature Regulator122................................................................................................................................................................
Dismantling Crankcase124................................................................................................................................................................
Removing And Installing Oil Pick-up Basket127................................................................................................................................................................
Removing Conrods127................................................................................................................................................................
Checking Conrods127................................................................................................................................................................
Replacing Oil Level Sight Glass127................................................................................................................................................................
Measuring Main And Big End Bearing Play128................................................................................................................................................................
Install Main Bearings129................................................................................................................................................................
Measuring Big End Bearing Play130................................................................................................................................................................
Assembling Engine131................................................................................................................................................................
Installing Conrod131................................................................................................................................................................
Installing Crankshaft132................................................................................................................................................................
Installing Auxiliary Shaft/timing Chains132................................................................................................................................................................
Installing Timing Chain Tensioning And Slide Rails132................................................................................................................................................................
Assembling Engine Block133................................................................................................................................................................
Installing Radial Seal On Crankshaft135................................................................................................................................................................
Installing Clutch Housing136................................................................................................................................................................
Installing Oil Pump137................................................................................................................................................................
Installing Auxiliary Shaft Drive138................................................................................................................................................................
Installing Pistons139................................................................................................................................................................
Installing Cylinders140................................................................................................................................................................
Installing Cylinder Head141................................................................................................................................................................
Adjusting Valve Clearances142................................................................................................................................................................
Installing Right Cylinder Head143................................................................................................................................................................
Installing Left Cylinder Head144................................................................................................................................................................
Installing Alternator Mount Cover146................................................................................................................................................................
Installing Magnetic Gate/belt Pulley146................................................................................................................................................................
Installing Alternator148................................................................................................................................................................
Installing Engin149................................................................................................................................................................
Engine Electrics150................................................................................................................................................................
Removing And Installing Coil And Ignition Lead156................................................................................................................................................................
Checking Ignition Coil Resistance156................................................................................................................................................................
Removing And Installing Alternator157................................................................................................................................................................
Checking Alternator160................................................................................................................................................................
Removing And Installing Starter Motor161................................................................................................................................................................
Dismantling/reassembling Starter Motor162................................................................................................................................................................
Checking Starter Motor162................................................................................................................................................................
Checking Starter Relay162................................................................................................................................................................
Renewing Carbon Brushes162................................................................................................................................................................
Removing And Installing Magnetic Gate163................................................................................................................................................................
Timing The Ignition164................................................................................................................................................................
Fuel Preparation And Control165................................................................................................................................................................
Removing And Installing Air Cleaner171................................................................................................................................................................
Removing And Installing Throttle Stub Pipe172................................................................................................................................................................
Removing And Installing Injectors173................................................................................................................................................................
Removing And Installing Motronic Control Unit173................................................................................................................................................................
Fuel Tank And Lines174................................................................................................................................................................
Removing And Installing Fuel Tank180................................................................................................................................................................
Removing And Installing Fuel Filter, Fuel Pump And Fuel Level Sensor182................................................................................................................................................................
Removing And Installing Fuel Filter183................................................................................................................................................................
Removing And Installing Fuel Pump And Fuel Level Sensor183................................................................................................................................................................
Checking Fuel Pump Pressure184................................................................................................................................................................
Exhaust System185................................................................................................................................................................
Clutch189................................................................................................................................................................
Gearbox191................................................................................................................................................................
Removing Clutch197................................................................................................................................................................
Installing Clutch197................................................................................................................................................................
Gearbox - Sectioned Drawing205................................................................................................................................................................
Removing And Installing Clutch Bear-ing/thrust Rod/release Lever207................................................................................................................................................................
Removing And Installing Gear Shift Pedal208................................................................................................................................................................
Removing Gearbox208................................................................................................................................................................
Replacing Shaft Seal On Neutral Switch210................................................................................................................................................................
Removing Gearbox Cover211................................................................................................................................................................
Removing Selector Drum212................................................................................................................................................................
Removing Gearbox Shafts213................................................................................................................................................................
Removing And Installing Input Shaft Sealing Ring At Housing End213................................................................................................................................................................
Removing/dismantling/reassembling Selector Shaft214................................................................................................................................................................
Removing And Installing Selector Shaft Seal215................................................................................................................................................................
Removing Deep-groove Ball Bearing From Selector Drum216................................................................................................................................................................
Installing Deep-groove Ball Bearing On Selector Drum217................................................................................................................................................................
Removing And Installing Deep-groove Ball Bearing And Race/roller Bearing For218................................................................................................................................................................
Idler Shaft218................................................................................................................................................................
Dismantling/reassembling Input Shaft219................................................................................................................................................................
Dismantling/reassembling Output Shaft223................................................................................................................................................................
Installing Gearbox Shafts227................................................................................................................................................................
Removing And Installing Output Shaft Seal228................................................................................................................................................................
Installing Selector Shaft229................................................................................................................................................................
Installing Selector Forks230................................................................................................................................................................
Installing Selector Drum230................................................................................................................................................................
Shimming Gearbox Shafts231................................................................................................................................................................
Shimming The Gearbox Shafts (without Clean Bearing)233................................................................................................................................................................
Shimming The Gearbox Shafts (with Clean Bearing)233................................................................................................................................................................
Removing And Installing Taper Roller Bearing Race234................................................................................................................................................................
Checking Friction Coefficient Of Input Shaft Taper Roller Bearing234................................................................................................................................................................
Installing Gearbox Cover235................................................................................................................................................................
Removing And Installing Input Shaft Seal At Housing Cover End236................................................................................................................................................................
Completing Assembly Of Gearbox237................................................................................................................................................................
Installing Gearbox238................................................................................................................................................................
Front Fork239................................................................................................................................................................
Steering239................................................................................................................................................................
Removing And Installing Telescopic Fork245................................................................................................................................................................
Removing And Installing Telescopic Fork Without Fork Bridge245................................................................................................................................................................
Rs] Removing And Installing Fork Bridge246................................................................................................................................................................
Gs/r/rt] Removing And Installing Fork Bridge246................................................................................................................................................................
Removing And Installing Slider Tube Bridge249................................................................................................................................................................
Rs] Checking Ball Joint Friction249................................................................................................................................................................
Gs/r/rt] Checking Ball Joint/ball Thrust Bearing Friction249................................................................................................................................................................
Dismantling/reassembling Telescopic Fork251................................................................................................................................................................
Assembling Telescopic Fork252................................................................................................................................................................
Measuring Telescopic Fork252................................................................................................................................................................
Removing And Installing Leading Link253................................................................................................................................................................
Dismantling/reassembling Leading Link253................................................................................................................................................................
Removing And Installing Front Suspension Strut254................................................................................................................................................................
Removing And Installing Ball Head254................................................................................................................................................................
R] Removing And Installing Steering Damper254................................................................................................................................................................
Checking The Steering Damper254................................................................................................................................................................
Removing And Installing Right Handlebar Fitting262................................................................................................................................................................
Rear Wheel Drive270................................................................................................................................................................
Removing Input Bevel Pinion278................................................................................................................................................................
Removing Rear Wheel Drive278................................................................................................................................................................
Disassembling Input Bevel Pinion280................................................................................................................................................................
Assembling Input Bevel Pinion282................................................................................................................................................................
Installing Input Bevel Pinion283................................................................................................................................................................
Removing And Installing Taper Roller Bearing In Rear Wheel Drive284................................................................................................................................................................
Removing Crown Wheel285................................................................................................................................................................
Installing Crown Wheel286................................................................................................................................................................
Checking/adjusting Backlash287................................................................................................................................................................
Checking Tooth Contact Pattern288................................................................................................................................................................
Shimming Housing Cover289................................................................................................................................................................
Installing Housing Cover289................................................................................................................................................................
Installing Splined Element289................................................................................................................................................................
Installing Rear Wheel Drive290................................................................................................................................................................
Removing And Installing Taper Roller Bearing292................................................................................................................................................................
Removing Rear Swinging Arm292................................................................................................................................................................
Removing And Installing Flexible Gaiter293................................................................................................................................................................
Installing Drive Shaft293................................................................................................................................................................
Removing Drive Shaft293................................................................................................................................................................
Installing Rear Swinging Arm294................................................................................................................................................................
Removing And Installing Suspension Strut295................................................................................................................................................................
Removing And Installing Front Brake Caliper302................................................................................................................................................................
Dismantling And Assembling Front Brake Caliper303................................................................................................................................................................
Dismantling Front Brake Caliper303................................................................................................................................................................
Assembling Front Brake Caliper303................................................................................................................................................................
Removing And Installing Rear Brake Caliper304................................................................................................................................................................
Rs] Dismantling And Assembling Rear Brake Caliper305................................................................................................................................................................
Assembling Rear Brake Caliper306................................................................................................................................................................
Removing And Installing Front Brake Disc308................................................................................................................................................................
Rs] Removing And Installing Rear Brake Disc (attached To Rear Wheel)309................................................................................................................................................................
Gs/r] Removing And Installing Rear Brake Disc (attached To Rear Wheel309................................................................................................................................................................
Rt/r] Removing And Installing Rear Brake Disc (attached To Rear Wheel)310................................................................................................................................................................
Rs] Removing And Installing Front Abs Sensor311................................................................................................................................................................
Gs/r] Removing And Installing Front Abs Sensor312................................................................................................................................................................
Rt] Removing And Installing Front Abs Sensor313................................................................................................................................................................
Abs] Adjusting Front Sensor Gap314................................................................................................................................................................
Rs] Removing And Installing Rear Abs Sensor315................................................................................................................................................................
Gs/r/rt] Removing And Installing Rear Abs Sensor316................................................................................................................................................................
Rs] Adjusting Rear Abs Sensor Gap317................................................................................................................................................................
Removing And Installing Rear Brake Master Cylinder320................................................................................................................................................................
Removing And Installing Brake Pedal321................................................................................................................................................................
Removing And Installing Abs Unit322................................................................................................................................................................
Removing The Abs Unit323................................................................................................................................................................
Installing The Abs Unit323................................................................................................................................................................
Removing And Installing Abs Relay And Relay Base324................................................................................................................................................................
Installing The Abs Relay324................................................................................................................................................................
Removing Abs Relay324................................................................................................................................................................
Removing Abs Relay Base325................................................................................................................................................................
Installing The Abs Relay Base325................................................................................................................................................................
Removing And Installing Front Wheel336................................................................................................................................................................
Installing Front Wheel336................................................................................................................................................................
Removing Front Wheel336................................................................................................................................................................
Rs/r/rt] Removing And Installing Rear Wheel (cast Alloy)339................................................................................................................................................................
Removing/installing Rear Wheel339................................................................................................................................................................
Gs/r] Removing And Installing Rear Wheel (spoked)340................................................................................................................................................................
Static Balancing Of Front Wheel/rear Wheel341................................................................................................................................................................
Checking Front/rear Wheel Rim For Runout342................................................................................................................................................................
Gs/r (spoked Wheel)] Removing And Installing Spokes343................................................................................................................................................................
Centering Horizontal Runout343................................................................................................................................................................
Gs/r (spoked Wheel)] Centering Wheel Rim343................................................................................................................................................................
General View, Frame350................................................................................................................................................................
Rt] Removing And Installing Fairing Sections353................................................................................................................................................................
Rt] Removing And Installing Upper Section Of Fairing356................................................................................................................................................................
Rt] Removing And Installing Fairing Holder357................................................................................................................................................................
Rt] Removing And Installing Rear Fairing359................................................................................................................................................................
Rt] Removing And Installing Number Plate Mount360................................................................................................................................................................
Rt] Removing And Installing Lower Rear Section361................................................................................................................................................................
Clean Thread + Loctite362................................................................................................................................................................
Loctite362................................................................................................................................................................
Rt/gs/r] Removing And Installing Center Stand362................................................................................................................................................................
Removing And Installing Side Stand363................................................................................................................................................................
Rt] Removing And Installing Left Footrest Plate364................................................................................................................................................................
Rt] Removing And Installing Right Footrest Plate365................................................................................................................................................................
Rt] Removing And Installing Frame366................................................................................................................................................................
Rs] Removing And Installing Front Mudguard367................................................................................................................................................................
Rs] Removing And Installing Adjustable Windshield371................................................................................................................................................................
Rs] Removing And Installing Top Section Of Fairing373................................................................................................................................................................
Rs] Removing And Installing Fairing Holder374................................................................................................................................................................
Removing And Installing Frame375................................................................................................................................................................
Rs] Removing And Installing Grab Handle/case Holder376................................................................................................................................................................
Rs] Removing And Installing Rear Fairing377................................................................................................................................................................
Rs] Removing And Installing Number Plate Bracket378................................................................................................................................................................
Rs] Removing And Installing Lower Rear Section379................................................................................................................................................................
Rs] Removing And Installing Rear Footrest Plate383................................................................................................................................................................
Master Cylinder To Footrest Plate 9384................................................................................................................................................................
Rs/r] Removing And Installing Front Footrest Plate384................................................................................................................................................................
Gs/r] Removing And Installing Front Mudguard385................................................................................................................................................................
Gs] Removing And Installing Front Fairing387................................................................................................................................................................
Gs] Removing And Installing Fairing Holder388................................................................................................................................................................
Gs/r] Removing And Installing Number Plate Bracket390................................................................................................................................................................
Gs/r] Removing And Installing Rear Mudguard391................................................................................................................................................................
Gs/r] Removing And Installing Rear Footrest Plate392................................................................................................................................................................
Gs] Removing And Installing Front Footrest Plate393................................................................................................................................................................
Checking Running Gear395................................................................................................................................................................
Measuring Wheel Track Offset395................................................................................................................................................................
General Electrical Equipment408................................................................................................................................................................
Rt] Removing And Installing Instrument Cluster451................................................................................................................................................................
Rt] Dismantling And Assembling Instrument Cluster451................................................................................................................................................................
Rs] Removing And Installing Instrument Cluster452................................................................................................................................................................
Rs] Dismantling And Assembling Instrument Cluster452................................................................................................................................................................
Gs] Removing And Installing Instrument Cluster453................................................................................................................................................................
Gs] Dismantling And Assembling Instrument Cluster453................................................................................................................................................................
R] Removing And Installing Instrument Cluster454................................................................................................................................................................

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