BMW R 1100 S Manuals

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BMW R 1100 S Repair Manual

BMW R 1100 S Repair Manual (302 pages)

Brand: BMW | Category: Motorcycle | Size: 26.54 MB
Table of contents
Table Of Contents5................................................................................................................................................................
Engine8................................................................................................................................................................
Tightening Torques And Table Of Consumables9................................................................................................................................................................
Engine Electrics15................................................................................................................................................................
Front Fork16................................................................................................................................................................
M6 Screw17................................................................................................................................................................
Table Of Consumables19................................................................................................................................................................
Pre-delivery Check21................................................................................................................................................................
Checking The Crate For Damage22................................................................................................................................................................
Filling And Charging The Battery23................................................................................................................................................................
Checking Clutch Fluid Level25................................................................................................................................................................
Checking Tyre Pressures26................................................................................................................................................................
Final Inspection And Function Check27................................................................................................................................................................
Maintenance28................................................................................................................................................................
Changing Oil In Gearbox29................................................................................................................................................................
Changing Oil In Rear Wheel Drive; Cleaning Inductive Signal Transmitter At Rear Wheel30................................................................................................................................................................
Replacing Fuel Filter31................................................................................................................................................................
Replacing Intake Air Filter Element33................................................................................................................................................................
Replacing Poly-v Belt34................................................................................................................................................................
Checking Brake Fluid Level35................................................................................................................................................................
Checking Front Brake Pad Wear36................................................................................................................................................................
Replacing Brake Pads, Front Brake37................................................................................................................................................................
Changing Brake Fluid And Bleeding Brake System38................................................................................................................................................................
Additional Information For [abs39................................................................................................................................................................
Checking Swinging Arm Bearings, Adjusting If Necessary42................................................................................................................................................................
Greasing The Side Stand Pivot43................................................................................................................................................................
Tightening Cylinder Heads44................................................................................................................................................................
Final Inspection With Road Safety And Functional Check46................................................................................................................................................................
Camshaft53................................................................................................................................................................
Removing Engine61................................................................................................................................................................
Disassembling Engine63................................................................................................................................................................
Removing Cylinder Head Cover64................................................................................................................................................................
Locking The Engine At Tdc65................................................................................................................................................................
Removing Valve Gear Holder67................................................................................................................................................................
Disassembling/assembling Valve Gear Holder68................................................................................................................................................................
Removing Cylinder Head70................................................................................................................................................................
Disassembling, Checking, Repairing And Reassembling Cylinder Head71................................................................................................................................................................
Removing Cylinder75................................................................................................................................................................
Removing And Disassembling Piston75................................................................................................................................................................
Checking Pistons And Cylinders76................................................................................................................................................................
Assembling Pistons76................................................................................................................................................................
Removing And Installing Conrod77................................................................................................................................................................
Removing And Installing Alternator Mount Cover With Engine Installed78................................................................................................................................................................
Replacing Radial Shaft Seal In Alternator Mount Cover78................................................................................................................................................................
Removing Alternator Mount Cover78................................................................................................................................................................
Removing Auxiliary Shaft Drive79................................................................................................................................................................
Removing Oil Pump80................................................................................................................................................................
Disassembling Crankcase82................................................................................................................................................................
Removing And Installing Oil Intake Strainers85................................................................................................................................................................
Removing Conrods85................................................................................................................................................................
Checking Conrods85................................................................................................................................................................
Replacing Oil Level Sight Glass85................................................................................................................................................................
Removing And Installing Oil Thermostat85................................................................................................................................................................
Measuring Crankshaft Bearing Play86................................................................................................................................................................
Measuring Big End Bearing Play88................................................................................................................................................................
Assembling Engine89................................................................................................................................................................
Installing Conrods89................................................................................................................................................................
Installing Crankshaft90................................................................................................................................................................
Installing Auxiliary Shaft/timing Chains90................................................................................................................................................................
Installing Timing Chain Tensioning And Slide Rails90................................................................................................................................................................
Assembling Engine Block91................................................................................................................................................................
Installing Radial Shaft Seals On Crankshaft94................................................................................................................................................................
Installing Clutch Housing95................................................................................................................................................................
Installing Oil Pump96................................................................................................................................................................
Installing Auxiliary Shaft Drive97................................................................................................................................................................
Installing Piston98................................................................................................................................................................
Installing Cylinder99................................................................................................................................................................
Tighten Nut To Wrench Angle100................................................................................................................................................................
Installing Cylinder Head100................................................................................................................................................................
Adjusting Valve Clearances101................................................................................................................................................................
Installing Right Cylinder Head102................................................................................................................................................................
Installing Left Cylinder Head103................................................................................................................................................................
Installing Alternator Mount Cover105................................................................................................................................................................
Installing Magnetic Gate/belt Pulley105................................................................................................................................................................
Installing Alternator107................................................................................................................................................................
Installing Engine108................................................................................................................................................................
Removing And Installing Coil And Ignition Leads113................................................................................................................................................................
Checking Ignition Coil Resistance113................................................................................................................................................................
Removing And Installing Alternator114................................................................................................................................................................
Disassembling/assembling Alternator115................................................................................................................................................................
Option 50 A116................................................................................................................................................................
Removing And Installing Starter Motor117................................................................................................................................................................
Disassembling/assembling Starter Motor118................................................................................................................................................................
Checking Starter Motor118................................................................................................................................................................
Checking Starter Relay118................................................................................................................................................................
Replacing Carbon Brushes118................................................................................................................................................................
Removing And Installing Magnetic Gate119................................................................................................................................................................
Timing The Ignition120................................................................................................................................................................
Fuel Preparation And Control121................................................................................................................................................................
Exhaust System137................................................................................................................................................................
Removing And Installing Clutch145................................................................................................................................................................
Removing Clutch145................................................................................................................................................................
Installing Clutch145................................................................................................................................................................
Removing And Installing Clutch Hydraulic Line146................................................................................................................................................................
Removing And Installing Clutch Slave Cylinder146................................................................................................................................................................
Filling/bleeding Clutch Line147................................................................................................................................................................
Removing Gearbox153................................................................................................................................................................
Replacing The Shaft Sealing Rings In The Gearbox Housing And Gearbox Cover155................................................................................................................................................................
Removing Gearbox Housing157................................................................................................................................................................
Removing Selector Drum158................................................................................................................................................................
Disassembling/assembling Selector Shaft158................................................................................................................................................................
Removing Gearbox Shafts159................................................................................................................................................................
Replacing Grooved Ball Bearing On Intermediate Shaft159................................................................................................................................................................
Disassembling/assembling Input Shaft160................................................................................................................................................................
Checking Endplay164................................................................................................................................................................
Checking/adjusting Fully Assembled Length Of Gearbox Shafts And Selector165................................................................................................................................................................
Shimming Selector Shaft169................................................................................................................................................................
Installing Input, Output And Intermediate Shafts170................................................................................................................................................................
Installing Selector Shaft171................................................................................................................................................................
Installing Selector Drum171................................................................................................................................................................
Installing Gearbox Housing172................................................................................................................................................................
Removing And Installing Telescopic Fork179................................................................................................................................................................
Disassembling/assembling Telescopic Fork181................................................................................................................................................................
Assembling Telescopic Fork181................................................................................................................................................................
Disassembling Telescopic Fork181................................................................................................................................................................
Measuring Telescopic Fork182................................................................................................................................................................
Removing And Installing Leading Link183................................................................................................................................................................
Disassembling/assembling Leading Link183................................................................................................................................................................
Removing And Installing Front Suspension Strut184................................................................................................................................................................
Removing Input Bevel Pinion199................................................................................................................................................................
Removing Rear Wheel Drive199................................................................................................................................................................
Disassembling Input Bevel Pinion201................................................................................................................................................................
Assembling Input Bevel Pinion202................................................................................................................................................................
Installing Input Bevel Pinion203................................................................................................................................................................
Removing And Disassembling Crown Wheel204................................................................................................................................................................
Assembling/installing Crown Wheel205................................................................................................................................................................
Checking/adjusting Backlash206................................................................................................................................................................
Checking Tooth Contact Pattern207................................................................................................................................................................
Shimming Housing Cover208................................................................................................................................................................
Installing Housing Cover208................................................................................................................................................................
Installing Sliding Element208................................................................................................................................................................
Removing And Installing Rear Swinging Arm209................................................................................................................................................................
Removing Rear Swinging Arm209................................................................................................................................................................
Removing And Installing Taper Roller Bearing210................................................................................................................................................................
Removing Drive Shaft210................................................................................................................................................................
Removing And Installing Flexible Gaiter210................................................................................................................................................................
Installing Rear Swinging Arm211................................................................................................................................................................
Installing Rear Wheel Drive212................................................................................................................................................................
Removing And Installing Suspension Strut213................................................................................................................................................................
Removing And Installing Front Brake Caliper219................................................................................................................................................................
Disassembling And Assembling Front Brake Caliper220................................................................................................................................................................
Assembling Front Brake Caliper220................................................................................................................................................................
Disassembling Front Brake Caliper220................................................................................................................................................................
Removing And Installing Rear Brake Caliper221................................................................................................................................................................
Disassembling And Assembling Rear Brake Caliper222................................................................................................................................................................
Assembling Rear Brake Caliper222................................................................................................................................................................
Disassembling Rear Brake Caliper222................................................................................................................................................................
Removing And Installing Front Brake Disc223................................................................................................................................................................
Removing And Installing Rear Brake Disc224................................................................................................................................................................
Removing And Installing Front Abs Sensor225................................................................................................................................................................
Adjusting Front Abs Sensor Gap226................................................................................................................................................................
Removing And Installing Rear Abs Sensor227................................................................................................................................................................
Adjusting Rear Abs Sensor Gap228................................................................................................................................................................
Removing And Installing Rear Brake Master Cylinder229................................................................................................................................................................
Checking And Adjusting Play Of Piston Rod229................................................................................................................................................................
Removing And Installing Footbrake Lever230................................................................................................................................................................
Removing And Installing Abs Unit231................................................................................................................................................................
Removing The Abs Unit231................................................................................................................................................................
Installing The Abs Unit232................................................................................................................................................................
Removing And Installing Abs Relay And Relay Socket233................................................................................................................................................................
Removing Abs Relay233................................................................................................................................................................
Installing The Abs Relay233................................................................................................................................................................
Installing The Abs Relay Base234................................................................................................................................................................
Removing And Installing Front Wheel243................................................................................................................................................................
Removing Front Wheel243................................................................................................................................................................
Installing Front Wheel243................................................................................................................................................................
Removing And Installing Wheel Bearings244................................................................................................................................................................
Removing And Installing Rear Wheel246................................................................................................................................................................
Static Balancing Of Front And Rear Wheels247................................................................................................................................................................
Checking Front/rear Wheel Rim For Runout248................................................................................................................................................................
Removing And Installing Fairing254................................................................................................................................................................
Removing And Installing Side Panels254................................................................................................................................................................
Removing And Installing Tank Trim254................................................................................................................................................................
Removing And Installing Rear Side Panels255................................................................................................................................................................
Removing And Installing Tail Section255................................................................................................................................................................
Removing And Installing Number-plate Carrier256................................................................................................................................................................
Removing And Installing Front Mudguard257................................................................................................................................................................
Removing And Installing Fairing Bracket258................................................................................................................................................................
Removing And Installing Front Frame259................................................................................................................................................................
Removing And Installing Main Frame261................................................................................................................................................................
Removing And Installing Frame Tail Section264................................................................................................................................................................
Removing And Installing Side Stand265................................................................................................................................................................
Checking Running Gear266................................................................................................................................................................
Measuring Wheel Track Offset266................................................................................................................................................................

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BMW R 1100 S Repair Manual

BMW R 1100 S Repair Manual (302 pages)

Brand: BMW | Category: Motorcycle | Size: 26.59 MB
Table of contents
Maintenance And General Instructions9................................................................................................................................................................
Table Of Contents10................................................................................................................................................................
Tightening Torques13................................................................................................................................................................
Checking The Crate For Damage22................................................................................................................................................................
In Case Of Damage In Germany22................................................................................................................................................................
In Case Of Damage In Importer Markets22................................................................................................................................................................
Inspecting Motorcycle For Damage22................................................................................................................................................................
Unpacking The Motorcycle22................................................................................................................................................................
Checking That Delivery Is Complete22................................................................................................................................................................
Filling And Charging The Battery23................................................................................................................................................................
Disengaging And Raising The Fuel Tank23................................................................................................................................................................
Checking Engine Oil Level When Cold, Adding Oil If Necessary24................................................................................................................................................................
Checking Brake Fluid Level25................................................................................................................................................................
Rear Brake25................................................................................................................................................................
Front Brake25................................................................................................................................................................
Checking Headlight Beam Angle, Adjusting If Necessary26................................................................................................................................................................
Checking Tyre Pressures26................................................................................................................................................................
Final Inspection And Function Check27................................................................................................................................................................
Handing Over The Motorcycle27................................................................................................................................................................
Final Cleaning27................................................................................................................................................................
Changing Oil In Gearbox29................................................................................................................................................................
Replacing Fuel Filter31................................................................................................................................................................
Checking Battery Fluid Level And33................................................................................................................................................................
Checking Brake Disc Wear36................................................................................................................................................................
Checking Front Brake Pad Wear36................................................................................................................................................................
Checking Rear Brake Pad Wear36................................................................................................................................................................
Replacing Brake Pads, Front Brake37................................................................................................................................................................
Replacing Brake Pads, Rear Brake37................................................................................................................................................................
Final Inspection With Road Safety And Functional Check46................................................................................................................................................................
Removing Engine61................................................................................................................................................................
Disassembling Engine63................................................................................................................................................................
Removing Cylinder Head Cover64................................................................................................................................................................
Locking The Engine At Tdc65................................................................................................................................................................
Removing And Installing Chain Tensioner66................................................................................................................................................................
Removing Valve Gear Holder67................................................................................................................................................................
Disassembling/assembling Valve Gear Holder68................................................................................................................................................................
Removing Cylinder Head70................................................................................................................................................................
Disassembling, Checking, Repairing And Reassembling Cylinder Head71................................................................................................................................................................
Removing Cylinder75................................................................................................................................................................
Removing And Disassembling Piston75................................................................................................................................................................
Checking Pistons And Cylinders76................................................................................................................................................................
Assembling Pistons76................................................................................................................................................................
Removing And Installing Conrod77................................................................................................................................................................
Removing And Installing Alternator Mount Cover With Engine Installed78................................................................................................................................................................
Replacing Radial Shaft Seal In Alternator Mount Cover78................................................................................................................................................................
Removing Alternator Mount Cover78................................................................................................................................................................
Removing Auxiliary Shaft Drive79................................................................................................................................................................
Removing Oil Pump80................................................................................................................................................................
Disassembling Crankcase82................................................................................................................................................................
Removing And Installing Oil Intake Strainers85................................................................................................................................................................
Removing Conrods85................................................................................................................................................................
Checking Conrods85................................................................................................................................................................
Replacing Oil Level Sight Glass85................................................................................................................................................................
Removing And Installing Oil Thermostat85................................................................................................................................................................
Measuring Crankshaft Bearing Play86................................................................................................................................................................
Measuring Big End Bearing Play88................................................................................................................................................................
Assembling Engine89................................................................................................................................................................
Installing Conrods89................................................................................................................................................................
Installing Crankshaft90................................................................................................................................................................
Installing Auxiliary Shaft/timing Chains90................................................................................................................................................................
Installing Timing Chain Tensioning And Slide Rails90................................................................................................................................................................
Assembling Engine Block91................................................................................................................................................................
Installing Radial Shaft Seals On Crankshaft94................................................................................................................................................................
Installing Clutch Housing95................................................................................................................................................................
Installing Oil Pump96................................................................................................................................................................
Installing Auxiliary Shaft Drive97................................................................................................................................................................
Installing Piston98................................................................................................................................................................
Installing Cylinder99................................................................................................................................................................
Installing Cylinder Head100................................................................................................................................................................
Adjusting Valve Clearances101................................................................................................................................................................
Installing Right Cylinder Head102................................................................................................................................................................
Installing Left Cylinder Head103................................................................................................................................................................
Installing Alternator Mount Cover105................................................................................................................................................................
Installing Magnetic Gate/belt Pulley105................................................................................................................................................................
Installing Alternator107................................................................................................................................................................
Installing Engine108................................................................................................................................................................
Removing And Installing Coil And Ignition Leads113................................................................................................................................................................
Checking Ignition Coil Resistance113................................................................................................................................................................
Removing And Installing Alternator114................................................................................................................................................................
Disassembling/assembling Alternator115................................................................................................................................................................
Option 50 A116................................................................................................................................................................
Removing And Installing Starter Motor117................................................................................................................................................................
Disassembling/assembling Starter Motor118................................................................................................................................................................
Checking Starter Motor118................................................................................................................................................................
Checking Starter Relay118................................................................................................................................................................
Replacing Carbon Brushes118................................................................................................................................................................
Removing And Installing Magnetic Gate119................................................................................................................................................................
Timing The Ignition120................................................................................................................................................................
Fuel Preparation And Control121................................................................................................................................................................
Exhaust System137................................................................................................................................................................
Removing And Installing Clutch145................................................................................................................................................................
Removing Clutch145................................................................................................................................................................
Installing Clutch145................................................................................................................................................................
Removing And Installing Clutch Hydraulic Line146................................................................................................................................................................
Removing And Installing Clutch Slave Cylinder146................................................................................................................................................................
Filling/bleeding Clutch Line147................................................................................................................................................................
Removing Gearbox153................................................................................................................................................................
Replacing The Shaft Sealing Rings In The Gearbox Housing And Gearbox Cover155................................................................................................................................................................
Removing Gearbox Housing157................................................................................................................................................................
Removing Selector Drum158................................................................................................................................................................
Disassembling/assembling Selector Shaft158................................................................................................................................................................
Removing Gearbox Shafts159................................................................................................................................................................
Replacing Grooved Ball Bearing On Intermediate Shaft159................................................................................................................................................................
Disassembling/assembling Input Shaft160................................................................................................................................................................
Checking Endplay164................................................................................................................................................................
Checking/adjusting Fully Assembled Length Of Gearbox Shafts And Selector165................................................................................................................................................................
Shimming Selector Shaft169................................................................................................................................................................
Installing Input, Output And Intermediate Shafts170................................................................................................................................................................
Installing Selector Shaft171................................................................................................................................................................
Installing Selector Drum171................................................................................................................................................................
Installing Gearbox Housing172................................................................................................................................................................
Removing And Installing Telescopic Fork179................................................................................................................................................................
Disassembling/assembling Telescopic Fork181................................................................................................................................................................
Assembling Telescopic Fork181................................................................................................................................................................
Measuring Telescopic Fork182................................................................................................................................................................
Removing And Installing Leading Link183................................................................................................................................................................
Disassembling/assembling Leading Link183................................................................................................................................................................
Removing And Installing Front Suspension Strut184................................................................................................................................................................
Removing Input Bevel Pinion199................................................................................................................................................................
Removing Rear Wheel Drive199................................................................................................................................................................
Disassembling Input Bevel Pinion201................................................................................................................................................................
Assembling Input Bevel Pinion202................................................................................................................................................................
Installing Input Bevel Pinion203................................................................................................................................................................
Removing And Disassembling Crown Wheel204................................................................................................................................................................
Assembling/installing Crown Wheel205................................................................................................................................................................
Checking/adjusting Backlash206................................................................................................................................................................
Checking Tooth Contact Pattern207................................................................................................................................................................
Shimming Housing Cover208................................................................................................................................................................
Installing Housing Cover208................................................................................................................................................................
Installing Sliding Element208................................................................................................................................................................
Removing And Installing Rear Swinging Arm209................................................................................................................................................................
Removing Rear Swinging Arm209................................................................................................................................................................
Removing And Installing Taper Roller Bearing210................................................................................................................................................................
Removing Drive Shaft210................................................................................................................................................................
Removing And Installing Flexible Gaiter210................................................................................................................................................................
Installing Rear Swinging Arm211................................................................................................................................................................
Installing Rear Wheel Drive212................................................................................................................................................................
Removing And Installing Suspension Strut213................................................................................................................................................................
Removing And Installing Front Brake Caliper219................................................................................................................................................................
Disassembling And Assembling Front Brake Caliper220................................................................................................................................................................
Assembling Front Brake Caliper220................................................................................................................................................................
Disassembling Front Brake Caliper220................................................................................................................................................................
Removing And Installing Rear Brake Caliper221................................................................................................................................................................
Disassembling And Assembling Rear Brake Caliper222................................................................................................................................................................
Assembling Rear Brake Caliper222................................................................................................................................................................
Disassembling Rear Brake Caliper222................................................................................................................................................................
Removing And Installing Front Brake Disc223................................................................................................................................................................
Removing And Installing Rear Brake Disc224................................................................................................................................................................
Removing And Installing Front Abs Sensor225................................................................................................................................................................
Adjusting Front Abs Sensor Gap226................................................................................................................................................................
Removing And Installing Rear Abs Sensor227................................................................................................................................................................
Adjusting Rear Abs Sensor Gap228................................................................................................................................................................
Removing And Installing Rear Brake Master Cylinder229................................................................................................................................................................
Checking And Adjusting Play Of Piston Rod229................................................................................................................................................................
Removing And Installing Footbrake Lever230................................................................................................................................................................
Removing And Installing Abs Unit231................................................................................................................................................................
Removing The Abs Unit231................................................................................................................................................................
Installing The Abs Unit232................................................................................................................................................................
Removing And Installing Abs Relay And Relay Socket233................................................................................................................................................................
Removing Abs Relay233................................................................................................................................................................
Installing The Abs Relay233................................................................................................................................................................
Installing The Abs Relay Base234................................................................................................................................................................
Removing And Installing Front Wheel243................................................................................................................................................................
Removing Front Wheel243................................................................................................................................................................
Installing Front Wheel243................................................................................................................................................................
Removing And Installing Wheel Bearings244................................................................................................................................................................
Removing And Installing Rear Wheel246................................................................................................................................................................
Static Balancing Of Front And Rear Wheels247................................................................................................................................................................
Checking Front/rear Wheel Rim For Runout248................................................................................................................................................................
Removing And Installing Fairing254................................................................................................................................................................
Removing And Installing Side Panels254................................................................................................................................................................
Removing And Installing Tank Trim254................................................................................................................................................................
Removing And Installing Rear Side Panels255................................................................................................................................................................
Removing And Installing Tail Section255................................................................................................................................................................
Removing And Installing Number-plate Carrier256................................................................................................................................................................
Removing And Installing Front Mudguard257................................................................................................................................................................
Removing And Installing Fairing Bracket258................................................................................................................................................................
Removing And Installing Front Frame259................................................................................................................................................................
Removing And Installing Main Frame261................................................................................................................................................................
Removing And Installing Frame Tail Section264................................................................................................................................................................
Removing And Installing Side Stand265................................................................................................................................................................
Checking Running Gear266................................................................................................................................................................
Measuring Wheel Track Offset266................................................................................................................................................................

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