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BMW R 1100 RT R1100 RS R850 1100 GS R 850 1100 R Motorcycle Repair Manual – PDF DOWNLOAD
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BMW R 1100 RT R1100 RS R850 1100 GS R 850 1100 R Motorcycle Repair Manual – PDF DOWNLOAD
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Description
BMW R 1100 RT R1100 RS R850 1100 GS R 850 1100 R Motorcycle Repair Manual – PDF DOWNLOAD
DESCRIPTION:
BMW R 1100 RT R1100 RS R850 1100 GS R 850 1100 R Motorcycle Repair Manual – PDF DOWNLOAD
Introduction :
This Repair Manual will help you to perform all the main maintenance and repair work correctly and efficiently. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and practical knowledge acquired at the BMW Training Centre. It is a contribution toward achieving even higher Service quality. A new issue of this repair manual will be published if amendments or additions (supplements) are needed. All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification.
• The Repair Manual is structured in the logical sequence of the work to be performed: Removal, Disassembling, Repair, Assembly, Installation.
• Work to be performed during an Inspection is described in Group “00”. The various inspection routines are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that work can take place without interruption.
• Use of the BMW special tools needed for certain tasks is described in the work instructions.
• Use of the BMW special tools needed for certain tasks is described in the work instructions.
If the need arises, repair instructions are also issued in the form of Service Information. This information is of course incorporated into the next issue of the Repair Manual. We also recommend, as an additional source of information.
TABLE OF CONTENTS:
BMW R 1100 RT R1100 RS R850 1100 GS R 850 1100 R Motorcycle Repair Manual – PDF DOWNLOAD
Repair Manual.................................................... 1 Introduction..................................................... 3 Contents......................................................... 4 Maintenance Schedule............................................. 6 Pre-delivery check............................................... 7 Service Data..................................................... 8 00 Maintenance and general instructions.......................... 9 Tightening torques R 1100 RS / R1100RT..................... 11 Tightening torques R850/1100GS und R850/1100R............ 20 Operating materials.......................................... 29 Key to maintenance intervals............................. 30 Change engine oil, renew oil filter element.................. 30 Change the oil in the gearbox and rear wheel drive........... 31 Changing oil in gearbox.................................. 31 Changing oil in rear wheel drive......................... 31 Checking battery acid level/topping up if necessar........... 32 Renewing air cleaner......................................... 32 Renewing fuel filter......................................... 33 Checking/renewing spark plugs................................ 37 Taking up slack at cylinder heads............................ 37 Checking/adjusting valve operating clearances................ 38 Adjusting Poly-V belt........................................ 39 Renewing Poly-V belt (40 000 km/24 000miles).............. 39 Checking brake pads and discs for wear/renewing.............. 40 Checking brake pads for wear............................. 40 Renewing brake pads – front brake........................ 40 [RS] Renewing brake pads - rear brake................... 41 [GS/R/RT] Renewing brake pads - rear brake.............. 41 Checking brake discs for wear............................ 41 Checking brake fluid level/topping up........................ 41 Bleeding/renewing the brake fluid using the handbr........... 42 Bleeding front brake circuit/renewing fluid.............. 42 Bleeding rear brake circuit/renewing brake fluid......... 42 Grease the centre stand [RS], side stand and clutc........... 43 [RS] Cleaning and greasing the windshield adjustin........... 43 [RS] Grease front suspension strut at its lower at........... 43 Checking/adjusting clutch operating clearance................ 44 Checking tightness of rear wheel studs....................... 45 [RS] Check tightness of screws at adjustable handl........... 45 [R] Check steering damper.................................... 45 Taking up slack on hose clips at intake stub pipen........... 45 Checking front wheel bearings/ checking tilt play ........... 45 Checking swinging arm bearings, adjusting if neces........... 45 Checking/adjusting throttle synchronisation and CO........... 46 Final inspection with road safety and functional c........... 50 11 Motor......................................................... 51 Technical Data............................................... 55 Sectioned drawing of engine.................................. 87 Lubricating oil circuit...................................... 88 Coolant circuit.............................................. 89 Cooling oil circuit (with oil thermostat).................... 90 Removing engine.............................................. 91 Dismantling engine...........................................104 Removing cylinder head cover.............................105 Locking the engine in the TDC position...................106 Removing and installing chain tensioner..................107 Removing valve gear holder...............................108 Dismantling/reassembling valve gear holder...............109 Removing cylinder head...................................111 Dismantling, checking, repairing and re-assembling.......112 Removing cylinder barrel.................................116 Removing/dismantling piston..............................116 Checking pistons and cylinders...........................117 Assemble pistons.........................................117 Removing/installing conrod...............................118 Removing and installing alternator cover with engi.......119 Removing alternator mount cover..........................119 Renewing radial shaft seal in alternator mount cov.......120 Renewing radial shaft seal for rotary breather...........120 Removing auxiliary-shaft drive...........................121 Removing oil pump........................................122 Oil temperature regulator................................122 Removing radial shaft seal on crank- shaft with en.......123 Dismantling crankcase....................................124 Removing crankshaft, auxiliary shaft and timing ch.......126 Removing and installing oil pick-up basket...............127 Replacing oil level sight glass..........................127 Removing conrods.........................................127 Checking conrods.........................................127 Measuring main and big end bearing play..................128 Install main bearings....................................129 Measuring big end bearing play...........................130 Assembling engine............................................131 Installing conrod........................................131 Installing crankshaft....................................132 Installing timing chain tensioning and slide rails.......132 Installing auxiliary shaft/timing chains.................132 Assembling engine block..................................133 Installing radial seal on crankshaft.....................135 Installing clutch housing................................136 Installing oil pump......................................137 Installing auxiliary shaft drive.........................138 Installing pistons.......................................139 Installing cylinders.....................................140 Installing cylinder head.................................141 Adjusting valve clearances...............................142 Installing right cylinder head...........................143 Installing left cylinder head............................144 Installing alternator mount cover........................146 Installing magnetic gate/belt pulley.....................146 Installing alternator....................................148 Installing engin.............................................149 12 Engine electrics..............................................150 Technical Data...............................................152 Removing and installing coil and ignition lead...............156 Checking ignition coil resistance........................156 Removing and installing alternator...........................157 Dismantling/reassembling alternator..........................159 Checking alternator......................................160 Checking armature for short to ground (earth)............160 Removing and installing starter motor........................161 Dismantling/reassembling starter motor.......................162 Renewing carbon brushes..................................162 Checking starter motor...................................162 Checking starter relay...................................162 Removing and installing magnetic gate........................163 Timing the ignition......................................164 13 Fuel preparation and control..................................165 Technical Data...............................................167 Removing and installing air cleaner..........................171 Removing and installing throttle stub pipe...................172 Removing and installing injectors........................173 Removing and installing Motronic control unit................173 16 Fuel tank and lines...........................................174 Technical Data...............................................176 Removing and installing fuel tank............................180 Removing and installing fuel filter, fuel pump and...........182 Removing and installing fuel filter......................183 Removing and installing fuel pump and fuel level s.......183 Checking fuel pump pressure..............................184 Removing and installing fuel distributor and press...........184 18 Exhaust system................................................185 Removing and installing exhaust system.......................187 Removing and installing muffler (silencer)...............187 Removing and installing front exhaust pipes..............188 21 Clutch........................................................189 Technical Data...............................................191 Removing and installing clutch...............................195 Removing clutch..........................................197 Installing clutch........................................197 Adjusting clutch operating clear- ance.......................198 23 Gearbox.......................................................199 Technical Data...............................................201 Gearbox - sectioned drawing..................................205 Removing and installing clutch bear-ing/thrust rod...........207 Removing and installing gear shift pedal.....................208 Removing gearbox.............................................208 Dismantling/reassembling.....................................210 Replacing shaft seal on neutral switch...................210 Removing gearbox cover...................................211 Removing selector drum...................................212 Removing gearbox shafts..................................213 Removing and installing input shaft sealing ring a.......213 Removing/dismantling/reassembling selector shaft.........214 Removing and installing selector shaft seal..............215 Removing deep-groove ball bearing from selector dr.......216 Removing taper roller bearing race from input shaf.......216 Installing deep-groove ball bearing on selector dr.......217 Installing taper roller bearing race on input shaf.......217 Removing and installing deep-groove ball bearing a.......218 Dismantling/reassembling input shaft.....................219 Disassembling/assembling input shaft (Clean Bearin.......221 Dismantling/reassembling output shaft....................223 Installing gearbox shafts................................227 Removing and installing output shaft seal................228 Installing selector shaft................................229 Installing selector forks................................230 Installing selector drum.................................230 Shimming gearbox shafts..................................231 Shimming the gearbox shafts (without Clean Bearing...........233 Example..................................................233 Shimming the gearbox shafts (with Clean Bearing).............233 Example..................................................233 Removing and installing taper roller bearing race........234 Checking friction coefficient of input shaft taper.......234 Installing gearbox cover.................................235 Removing and installing input shaft seal at housin.......236 Completing assembly of gearbox...........................237 Installing gearbox...........................................238 31 Front fork....................................................239 Technical Data...............................................241 Removing and installing telescopic fork......................245 Removing and installing telescopic fork without fo.......245 [RS] Removing and installing fork bridge.................246 [GS/R/RT] Removing and installing fork bridge............246 Removing and installing slider tube bridge...............249 [RS] Checking ball joint friction........................249 [GS/R/RT] Checking ball joint/ball thrust bearing .......249 Dismantling/reassembling telescopic fork....................251 Dismantling telescopic fork..............................251 Assembling telescopic fork...............................252 Measuring telescopic fork....................................252 Removing and installing leading link.........................253 Dismantling/reassembling leading link........................253 Removing and installing front suspension strut..............254 [R] Removing and installing steering damper..................254 Removing and installing ball head........................254 Checking the steering damper.............................254 32 Steering......................................................255 Technical Data...............................................257 Removing and installing left handlebar fitting...............261 Removing and installing right handlebar fitting.............262 [RS] Removing and installing handlebar......................263 [GS/R/RT] Removing and installing handlebar..................264 Removing and installing wire cable distributor blo...........265 Removing and installing throttle cable.......................266 Removing and installing cold-start cable.....................268 Removing and installing clutch cable.........................269 33 Rear wheel drive..............................................270 Technical Data...............................................272 Rear wheel drive-sectioned drawing...........................276 Removing, dismantling, reassembling and installing...........278 Removing rear wheel drive................................278 Removing input bevel pinion..............................278 Disassembling input bevel pinion.........................280 Assembling input bevel pinion............................282 Installing input bevel pinion............................283 Removing and installing taper roller bearing in re.......284 Removing crown wheel.....................................285 Installing crown wheel...................................286 Checking/adjusting backlash..............................287 Checking tooth contact pattern...........................288 Shimming housing cover...................................289 Installing housing cover.................................289 Installing splined element...............................289 Installing rear wheel drive..............................290 Removing, dismantling, reassembling and installing...........292 Removing rear swinging arm...............................292 Removing and installing taper roller bearing.............292 Removing and installing flexible gaiter..................293 Removing drive shaft.....................................293 Installing drive shaft...................................293 Installing rear swinging arm.............................294 Removing and installing suspension strut....................295 34 Brakes........................................................296 Technical Data...............................................298 Removing and installing front brake caliper..................302 Dismantling and assembling front brake caliper...............303 Dismantling front brake caliper..........................303 Assembling front brake caliper...........................303 Removing and installing rear brake caliper...................304 [RS] Dismantling and assembling rear brake caliper...........305 Dismantling rear brake caliper...........................305 Assembling rear brake caliper............................306 [GS/R/RT] Dismantling and re- assembling rear brak...........307 Dismantling rear brake caliper...........................307 Assembling rear brake caliper............................307 Removing and installing front brake disc.....................308 [RS] Removing and installing rear brake disc (atta...........309 [GS/R] Removing and installing rear brake disc (at...........309 [RT/R] Removing and installing rear brake disc (at...........310 [RS] Removing and installing front ABS sensor................311 [GS/R] Removing and installing front ABS sensor..............312 [RT] Removing and installing front ABS sensor................313 [ABS] Adjusting front sensor gap.............................314 Marking sensor wheel.....................................314 Checking and adjusting sensor gap........................314 [RS] Removing and installing rear ABS sensor.................315 [GS/R/RT] Removing and installing rear ABS sensor............316 [RS] Adjusting rear ABS sensor gap...........................317 Marking sensor wheel.....................................317 Checking and adjusting sensor gap........................317 [GS/R/RT] Adjusting rear ABS sensor gap......................318 Marking sensor wheel.....................................318 Checking and adjusting sensor gap........................318 Removing, installing, dismantling and assembling f...........319 Removing and installing rear brake master cylinder...........320 Checking and adjusting relief clear- ance of pisto.......320 Removing and installing brake pedal..........................321 Removing and installing ABS unit.............................322 Removing the ABS unit....................................323 Installing the ABS unit..................................323 Removing and installing ABS relay and relay base.............324 Removing ABS relay.......................................324 Installing the ABS relay.................................324 Removing ABS relay base..................................325 Installing the ABS relay base............................325 Removing and installing brake line (with ABS)................327 Removing and installing front ABS brake line.............327 Removing and installing rear ABS brake line..................328 36 Wheels and tyres..............................................330 Technical Data...............................................332 Removing and installing front wheel..........................336 Removing front wheel.....................................336 Installing front wheel...................................336 Removing and installing wheel bearings...................337 [RS/R/RT] Removing and installing rear wheel (cast...........339 Removing rear wheel......................................339 Installing rear wheel....................................339 [GS/R] Removing and installing rear wheel (spoked)...........340 Removing rear wheel......................................340 Installing rear wheel....................................340 Static balancing of front wheel/rear wheel...................341 Checking front/rear wheel rim for runout.....................342 [GS/R (spoked wheel)] Removing and installing spok...........343 [GS/R (spoked wheel)] Centering wheel rim....................343 Centering horizontal runout..............................343 46 Frame.........................................................344 Technical Data...............................................346 General view, frame..........................................350 [RT] General view of fairing sections........................351 [RT] Removing and installing front mudguard..................352 [RT] Removing and installing fairing sections................353 [RT] Removing and installing wind- shield....................354 [RT] Removing and installing inner fairing panel.............355 [RT] Removing and installing upper section of fair...........356 [RT] Removing and installing fairing holder..................357 [RT] Removing and installing luggage rack/case hol...........358 [RT] Removing and installing rear fairing....................359 [RT] Removing and installing number plate mount...........360 [RT] Removing and installing lower rear section..............361 [RT/GS/R] Removing and installing center stand...............362 Removing and installing side stand...........................363 [RT] Removing and installing left footrest plate.............364 [RT] Removing and installing right footrest plate............365 [RT] Removing and installing frame...........................366 [RS] Removing and installing front mudguard..................367 [RS] Removing and installing side sections of fair...........368 [RS] Removing and installing side sections of full...........369 [RS] Removing and installing wind- shield....................370 [RS] Removing and installing adjustable windshiel...........371 [RS] Removing and installing inner fairing panel.............372 [RS] Removing and installing top section of fairin...........373 [RS] Removing and installing fairing holder..................374 Removing and installing frame................................375 [RS] Removing and installing grab handle/case hold...........376 [RS] Removing and installing rear fairing....................377 [RS] Removing and installing number plate bracket............378 [RS] Removing and installing lower rear section..............379 Removing and installing rear section of frame................380 [RS] Removing and installing center stand....................381 [RS] Removing and installing rear footrest plate.............383 [RS/R] Removing and installing front footrest plat...........384 [GS/R] Removing and installing front mudguard................385 [GS] Removing and installing windshield.....................386 [GS] Removing and installing front fairing...................387 [GS] Removing and installing fairing holder..................388 [GS] Removing and installing luggage rack...................389 [GS/R] Removing and installing number plate bracke...........390 [GS/R] Removing and installing rear mudguard.................391 [GS/R] Removing and installing rear footrest plate...........392 [GS] Removing and installing front footrest plate............393 [R] Removing and installing rear fairing.....................394 Checking running gear........................................395 Measuring wheel track offset.............................395 51 Equipment.....................................................397 Removing and installing ignition switch/steering l...........399 Removing and installing ignition/light switch............399 Removing and installing lock barrel......................399 Removing and installing lock barrel for fuel tank ...........400 [RS/RT] Removing and installing dualseat lock................401 Removing and installing lock barrel......................401 [GS] Removing and installing dualseat lock..................401 Removing and installing lock barrel......................401 [R] Removing and installing dualseat lock...................402 Removing and installing lock barrel......................402 [GS] Removing and installing helmet lock.....................402 [RT] Removing and installing storage compartment l...........402 52 Seat..........................................................403 [RT] Dismantling and assembling dualseat.....................405 [RS] Dismantling and assembling dualseat.....................406 [GS/R] Dismantling and assembling dualseat...................407 61 General electrical equipment..................................408 Technical Data...............................................410 Removing and installing central electrical equipme...........414 Dismantling/assembling central electrical equipmen...........414 Relay positions (central electrical equipment box)...........415 Frame wiring harness [ABS]...................................416 Installing wiring harness/connections in central e.......417 Installing wiring harness in central electrical eq.......418 [RT] Wiring harness View from left.......................419 [RT] Wiring harness View from right......................423 [RT] Wiring harness at fairing holder....................426 [RT] Wiring harness at instrument cluster...............427 [RS] Wiring harness View from left.......................428 [RS] Wiring harness View from right......................432 [RS] Wiring harness at left switch unit.................435 [RS] Wiring harness at right switch unit................436 [GS] Wiring harness View from left.......................437 [GS] Wiring harness View from right......................441 Removing and installing battery holder.......................444 62 Instruments...................................................445 Technical Data...............................................447 [RT] Removing and installing instrument cluster.............451 [RT] Dismantling and assembling instrument cluster...........451 [RS] Removing and installing instrument cluster.............452 [RS] Dismantling and assembling instrument cluster...........452 [GS] Removing and installing instrument cluster.............453 [GS] Dismantling and assembling instrument cluster...........453 [R] Removing and installing instrument cluster..............454 63 Lights........................................................455 Technica Data................................................457 [RT] Removing and installing headlight.......................461 Adjusting headlight......................................461 [RS] Removing and installing headlight.......................462 Adjusting headlight......................................462 [GS] Removing and installing headlight.......................463 Adjusting headlight......................................464 [GS] Removing and installing front flashing turn i...........464 [R] Removing and installing headlight........................464 Adjusting headlight......................................464
Questions? Email us: [email protected]
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
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