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BMW R1100S Factory Service Manual – PDF DOWNLOAD
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Description
BMW R1100S Factory Service Manual
FILE DETAILS:
BMW R1100S Factory Service Manual
Language : English
Pages : 302
Downloadable : YES
Format : PDF
Size : 25.3 MB
DESCRIPTION:
BMW R1100S Factory Service Manual
INTRODUCTION:
This repair manual will help you to perform all the main maintenance and repair work correctly and efficiently. It should be consulted regularly by workshop personnel as an addition to the practical and theoretical knowledge obtained in Training School courses.
- It is a contribution towards achieving even higher Service quality. 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, Disassembly, Repair, Assembly, Installation. l The entire contents are divided into individual chapters, corresponding to the Construction Groups.
TABLE OF CONTENTS:
BMW R1100S Factory Service Manual
Repair Manual........................................................ 1 Introduction......................................................... 3 Contents............................................................. 5 Maintenance schedule................................................. 7 Pre-delivery check................................................... 8 00 Maintenance and general instructions.............................. 9 Tightening torques............................................... 13 Table of consumables............................................. 19 Pre-delivery check............................................... 21 General view of crated motorcycle................................ 21 Checking the crate for damage.................................... 22 In case of damage in Germany................................. 22 In case of damage in importer markets........................ 22 Unpacking the motorcycle......................................... 22 Installing remaining items on motorcycle......................... 22 Inspecting motorcycle for damage................................. 22 Checking that delivery is complete............................... 22 Filling and charging the battery................................. 23 Disengaging and raising the fuel tank........................ 23 Filling and charging the battery............................. 23 Checking engine oil level when cold, adding oil if............... 24 Checking clutch fluid level...................................... 25 Checking brake fluid level....................................... 25 Rear brake................................................... 25 Front brake.................................................. 25 Checking headlight beam angle, adjusting if necess............... 26 Checking tightness of rear wheel studs........................... 26 Checking tyre pressures.......................................... 26 Final inspection and function check.............................. 27 Final cleaning................................................... 27 Handing over the motorcycle...................................... 27 Maintenance...................................................... 28 Key to maintenance intervals..................................... 28 Reading out MoDiTeC fault memory................................. 28 (Inspections I, II, III and IV).............................. 28 Changing engine oil, replacing oil filter element................ 28 (Inspections I, II, III and IV).............................. 28 Changing oil in gearbox.......................................... 29 (Inspections III and IV)..................................... 29 or every 2 years at the latest............................... 29 Changing oil in rear wheel drive; cleaning inducti............... 30 (Inspections I, III and IV).................................. 30 Every 40 000 km (24 000 miles) or every 2 years at........... 30 Replacing fuel filter............................................ 31 (Inspection III)............................................. 31 In normal operating conditions every 40 000 km (24........... 31 Checking battery fluid level and topping up if nec............... 33 (Inspections III and IV)..................................... 33 Replacing intake air filter element.............................. 33 (Inspection III)............................................. 33 In very dirty and dusty operating conditions, repl........... 33 Replacing Poly-V belt............................................ 34 (every 60 000 km/36 000 miles)............................... 34 (Inspection III)............................................. 34 Poly-V belt adjusting procedure:............................. 34 Checking brake fluid level....................................... 35 Front brake.................................................. 35 Rear brake................................................... 35 Checking brake pads and discs for wear/replacing................. 36 (Inspections II and III)..................................... 36 Checking front brake pad wear................................ 36 Checking rear brake pad wear................................. 36 Checking brake disc wear..................................... 36 Replacing brake pads, front brake............................ 37 Replacing brake pads, rear brake............................. 37 Changing brake fluid and bleeding brake system................... 38 Change the brake fluid annually.............................. 38 (Inspection IV).............................................. 38 Bleeding front brake circuit/changing brake fluid............ 38 Additional information for [ABS]......................... 39 Bleeding rear brake circuit/changing brake fluid............. 40 Checking clutch fluid level...................................... 41 (Inspections I, II and III).................................. 41 Changing the clutch fluid........................................ 41 (Inspections III and IV)..................................... 41 Every 40 000 km (24 000 miles) or every 2 years at........... 41 Checking tightness of rear wheel studs........................... 42 (Inspection I)............................................... 42 Checking rear wheel bearing play by tilting wheel................ 42 (Inspection III)............................................. 42 Checking swinging arm bearings, adjusting if neces............... 42 (Inspections I and III)...................................... 42 Greasing the side stand pivot.................................... 43 (Inspections I, II and III).................................. 43 Checking function of side stand switch........................... 43 (Inspections I, II, III and IV).............................. 43 Checking/replacing spark plugs................................... 43 (Inspection II) check/(Inspection III) replace............... 43 Tightening cylinder heads........................................ 44 (Inspection I)............................................... 44 Checking/adjusting valve clearances.............................. 44 (Inspections I, II and III).................................. 44 Checking throttle cable for ease of movement, abra............... 45 (Inspections I, II, III and IV).............................. 45 Final inspection with road safety and functional c............... 46 (Inspections I, II, III and IV).............................. 46 Road safety check............................................ 46 Roadworthiness check......................................... 46 11 Engine............................................................ 47 Cutaway drawing of engine Lubricating-oil circuit................ 57 Cooling-oil circuit.............................................. 59 Removing engine.................................................. 61 Disassembling engine............................................. 63 Removing cylinder head cover................................. 64 Locking the engine at TDC.................................... 65 Firing TDC............................................... 65 Removing and installing chain tensioner...................... 66 Work instructions, timing-chain tensioner................ 66 Removing valve gear holder................................... 67 Disassembling/assembling valve gear holder................... 68 Removing cylinder head....................................... 70 Disassembling, checking, repairing and reassemblin........... 71 Removing and installing valves........................... 71 Removing valve stem seals................................ 71 Checking valves for wear................................. 72 Remachining valve seat................................... 72 Checking and repairing cylinder head..................... 72 Checking valve guide for wear............................ 72 Replacing valve guides................................... 73 Installing valve and valve stem seal..................... 74 Removing cylinder............................................ 75 Removing and disassembling piston............................ 75 Checking pistons and cylinders............................... 76 Assembling pistons........................................... 76 Removing and installing conrod............................... 77 Removing and installing alternator mount cover wit........... 78 Removing alternator mount cover.............................. 78 Replacing radial shaft seal in alternator mount co........... 78 Removing auxiliary shaft drive............................... 79 Removing oil pump............................................ 80 Removing radial shaft seal from crankshaft with en........... 81 Disassembling crankcase...................................... 82 Removing crankshaft, auxiliary shaft and timing ch........... 84 Removing and installing oil intake strainers................. 85 Replacing oil level sight glass.............................. 85 Removing and installing oil thermostat....................... 85 Removing conrods............................................. 85 Checking conrods............................................. 85 Measuring crankshaft bearing play............................ 86 Measuring radial bearing play............................ 86 Installing main bearings................................. 87 Measuring axial bearing play............................. 87 Measuring big end bearing play............................... 88 Assembling engine................................................ 89 Installing conrods........................................... 89 Installing crankshaft........................................ 90 Installing timing chain tensioning and slide rails........... 90 Installing auxiliary shaft/timing chains..................... 90 Assembling engine block...................................... 91 Installing radial shaft seals on crankshaft.................. 94 Installing the crankshaft-end radial shaft seal.......... 94 Installing the clutch-end radial shaft seal.............. 94 Installing clutch housing.................................... 95 Installing oil pump.......................................... 96 Installing auxiliary shaft drive............................. 97 Installing piston............................................ 98 Installing cylinder.......................................... 99 Installing cylinder head.....................................100 Adjusting valve clearances...................................101 Installing right cylinder head...............................102 Adjustment specification.................................102 Installing left cylinder head................................103 Adjustment specification.................................103 Installing alternator mount cover............................105 Installing magnetic gate/belt pulley.........................105 Timing the ignition......................................106 Installing alternator........................................107 Installing engine................................................108 12 Engine electrics..................................................109 Removing and installing coil and ignition leads..................113 Checking ignition coil resistance............................113 Removing and installing alternator...............................114 Poly-V belt adjusting procedure:.............................114 Disassembling/assembling alternator..............................115 Checking alternator..........................................115 Checking armature for short to ground (earth)................115 Disassembling/assembling alternator..............................116 (Option 50 A)....................................................116 Checking alternator..........................................116 Checking armature for short to ground (earth)................116 Removing and installing starter motor............................117 Disassembling/assembling starter motor...........................118 Replacing carbon brushes.....................................118 Checking starter motor.......................................118 Checking starter relay.......................................118 Removing and installing magnetic gate............................119 Timing the ignition..........................................120 13 Fuel preparation and control......................................121 Removing and installing air filter housing.......................125 Removing and installing throttle- valve stub pipe................126 Removing and installing throttle-valve potentiomet...............127 Removing and installing Motronic control unit....................127 16 Fuel tank and lines...............................................129 Removing and installing fuel tank................................133 Removing and installing fuel filter, fuel pump and...............134 Removing and installing fuel filter..........................134 Removing and installing fuel pump and fuel level s...........135 Checking fuel pump pressure..............................135 Removing and installing fuel distributor and press...............135 18 Exhaust system....................................................137 Removing and installing exhaust system...........................139 Removing and installing silencer (muffler)...................139 Removing and installing exhaust manifolds....................139 21 Clutch............................................................141 Removing and installing clutch hydraulic line....................146 Removing and installing clutch slave cylinder....................146 Filling/bleeding clutch line.....................................147 Removing and installing clutch...................................145 Removing clutch..............................................145 Installing clutch............................................145 23 Gearbox...........................................................149 Removing and installing gear-shift lever.........................153 Removing gearbox.................................................153 Replacing the shaft sealing rings in the gearbox h...........155 Replacing input shaft sealing ring at input end..........155 Replacing output shaft sealing ring......................155 Replacing input shaft sealing ring at output end.........156 Replacing shaft sealing ring for selector drum...........156 Replacing sealing ring for selector shaft................156 Disassembling gearbox............................................157 Removing gearbox housing.....................................157 Removing selector drum.......................................158 Disassembling/assembling selector shaft......................158 Removing gearbox shafts......................................159 Replacing grooved ball bearing on intermediate sha...........159 Disassembling/assembling input shaft.........................160 Disassembling input shaft................................160 Assembling input shaft...................................161 Disassembling/assembling output shaft........................162 Disassembling output shaft...............................162 Assembling output shaft..................................163 Checking endplay.............................................164 Checking/adjusting fully assembled length of gearb...........165 Checking/adjusting fully assembled length of inter.......165 Checking/adjusting fully assembled length of outpu.......166 Checking/adjusting fully assembled length of input.......167 Checking/adjusting fully assembled length of selec.......168 Shimming selector shaft......................................169 Assembling gearbox...............................................170 Installing input, output and intermediate shafts.............170 Installing selector shaft....................................171 Installing selector drum.....................................171 Installing gearbox housing...................................172 31 Front fork........................................................175 Removing and installing telescopic fork..........................179 Removing and installing telescopic fork......................179 Removing and installing ball joint in slider tube .......180 Removing and installing ball joint in fork bridge........180 Disassembling/assembling telescopic fork.........................181 Disassembling telescopic fork................................181 Assembling telescopic fork...................................181 Measuring telescopic fork........................................182 Examining slider tube bridge and fork bridge.................182 Checking runout of fixed tube................................182 Checking runout of slider tube...............................182 Removing and installing leading link.............................183 Disassembling/assembling leading link............................183 Removing and installing front suspension strut...................184 32 Steering..........................................................185 Removing and installing left handlebar fitting...................189 Removing and installing right handlebar fitting..................190 Removing and installing handlebar................................191 Removing and installing Bowden- cable divider, Bow...............192 Disassembling Bowden-cable divider...............................193 33 Rear wheel drive..................................................195 Removing, disassembling, reassembling and installi...............199 Removing rear wheel drive....................................199 Removing input bevel pinion..................................199 Disassembling input bevel pinion.............................201 Removing needle roller bearing for input bevel pin.......201 Installing needle roller bearing for input bevel p.......201 Assembling input bevel pinion................................202 Installing input bevel pinion................................203 Removing and disassembling crown wheel.......................204 Assembling/installing crown wheel............................205 Checking/adjusting backlash..................................206 Checking tooth contact pattern...............................207 Shimming housing cover.......................................208 Installing housing cover.....................................208 Installing sliding element...................................208 Removing and installing rear swinging arm........................209 Removing rear swinging arm...................................209 Removing and installing taper roller bearing.................210 Removing and installing flexible gaiter......................210 Removing drive shaft.........................................210 Checking universal joint for wear........................210 Installing drive shaft.......................................210 Installing rear swinging arm.................................211 Installing rear wheel drive..................................212 Removing and installing suspension strut.........................213 34 Brakes............................................................215 Removing and installing front brake caliper......................219 Disassembling and assembling front brake caliper.................220 Disassembling front brake caliper............................220 Assembling front brake caliper...............................220 Removing and installing rear brake caliper.......................221 Disassembling and assembling rear brake caliper..................222 Disassembling rear brake caliper.............................222 Assembling rear brake caliper................................222 Removing and installing front brake disc.........................223 Removing and installing rear brake disc..........................224 Removing and installing front ABS sensor.........................225 Adjusting front ABS sensor gap...................................226 Marking sensor wheel.........................................226 Checking and adjusting sensor gap............................226 Removing and installing rear ABS sensor..........................227 Adjusting rear ABS sensor gap....................................228 Marking sensor wheel.........................................228 Checking and adjusting sensor gap............................228 Removing and installing rear brake master cylinder...............229 Checking and adjusting play of piston rod....................229 Removing and installing footbrake lever..........................230 Removing and installing ABS unit.................................231 Removing the ABS unit........................................231 Installing the ABS unit......................................232 Removing and installing ABS relay and relay socket...............233 Removing ABS relay...........................................233 Installing the ABS relay.....................................233 Removing ABS relay socket....................................234 Installing the ABS relay base................................234 Removing and installing brake line...............................235 Removing and installing front brake line.....................235 Removing and installing rear brake line......................236 36 Wheels and tyres..................................................239 Removing and installing front wheel..............................243 Removing front wheel.........................................243 Installing front wheel.......................................243 Removing and installing wheel bearings.......................244 Removing and installing rear wheel...............................246 Static balancing of front and rear wheels........................247 Checking front/rear wheel rim for runout.........................248 46 Frame.............................................................249 Exploded view of fairing sections................................253 Removing and installing fairing..................................254 Removing and installing side panels..........................254 Removing and installing tank trim............................254 Removing and installing fairing..............................254 Removing and installing rear side panels.....................255 Removing and installing tail section.........................255 Removing and installing rear mudguard............................256 Removing and installing number-plate carrier.....................256 Removing and installing front mudguard...........................257 Removing and installing fairing bracket..........................258 Removing and installing front frame..............................259 Removing and installing main frame...............................261 Removing and installing frame tail section.......................264 Removing and installing side stand...............................265 Checking running gear............................................266 Measuring wheel track offset.................................266 51 Equipment.........................................................269 Removing and installing ignition switch/steering l...............271 Removing and installing ignition/light switch................271 Removing and installing lock barrel..........................271 Drilling out lock barrel.................................271 Removing and installing dualseat lock............................271 Removing and installing lock barrel for fuel tank ...............272 Drilling out lock barrel.....................................272 52 Seat..............................................................273 Removing and installing seat.....................................275 61 General electrical equipment......................................277 Relay positions (central electrical equipment box)...............281 Fuse assignments.............................................281 Left fuse box................................................281 Right fuse box...............................................281 Frame wiring harness.............................................282 Wiring harness View from left................................283 Wiring harness View from right...............................287 62 Instruments.......................................................291 Removing and installing instrument panel.........................295 Disassembling and assembling instrument panel....................295 63 Lights............................................................297 Removing and installing headlight................................301 Adjusting headlight..........................................301
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