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BMW R 1100 GS + Adventure, Repair Manual

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BMW R 1100 GS + Adventure Repair Manual Download Page 1

BMW Motorcycle
After Sales

R 1100 RT
R 1100 RS

R 850/1100 GS
R 850/1100 R

Repair Manual

Summary of Contents for R 1100 GS + Adventure

Page 1: ...BMW Motorcycle After Sales R 1100 RT R 1100 RS R 850 1100 GS R 850 1100 R Repair Manual ...

Page 2: ...After Sales UX VS 2 All rights reserved Not to be reprinted translated or duplicated either wholly or in part without prior written permission Errors and omissions excepted subject to technical amendment Produced in Germany 02 00 ...

Page 3: ...g to the Construction Groups 11 10 Chap Page number within chapter 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...

Page 4: ...al instructions 11 Motor 12 Engine electrics 13 Fuel preparation and control 16 Fuel tank and lines 18 Exhaust system 21 Clutch 23 Gearbox 31 Front fork 32 Steering 33 Rear wheel drive Continuation Contents Back Group Chapter ...

Page 5: ...34 Brakes 36 Wheels and tyres 46 Frame 51 Equipment 52 Seat 61 General electrical equipment 62 Instruments 63 Lights Back Continuation Group Chapter ...

Page 6: ...just if necessary Check steering damper R850 1100R Lubricate side stands centre stand R 1100 RS and nipple for clutch cable assembly Check side stand switch for damage and correct operation b SI 46 033 96 722 Check fit of rear wheel bolts Check bolts of control arm to specified torque Clean and grease shaft for windshield adjustment R 1100 RS Grease lower eye of front spring strut R 1100 RS slide ...

Page 7: ...ts keys optional extras Check headlight basic setting adjust if necessary Check front and rear wheel brake fluid levels Check torque setting of the rear wheel retaining studs Check tyre pressure Check engine oil level top up if necessary Fuel the motorcycle Check basic clutch setting adjust if necessary Safety operating check as final inspection idle speed clutch gear shifting steering front and r...

Page 8: ...m play mm play mm play Clutch cable adjustment wire cable at handle bar lever at lever 12 0 7 0 mm thread mm play Tyre pressure depending on load and speed front 2 2 2 5 rear 2 5 2 9 bar bar Tightening torques Oilfilter Engine oil drain plug Gearbox oil drain plug Rear wheel drive oil drain plug Locknut valve adjustment Cylinder head cover Generator to bracket Tension multiple ripped belt Poly V S...

Page 9: ...p if necessary cleaning greasing battery posts 24 Inspection III IV 24 Renewing air cleaner 24 Inspection III 24 Renewing fuel filter 25 Inspektion III 25 Checking renewing spark plugs 29 Inspection II III 29 Taking up slack at cylinder heads 29 Inspection I 29 Checking adjusting valve operating clearances 30 Inspection I II III 30 Adjusting Poly V belt 31 Inspection I II III 31 Renewing Poly V be...

Page 10: ... Inspection III 35 RS Grease front suspension strut at its lower attachment lug version with plain bearing only 35 Inspection II III 35 Checking adjusting clutch operating clearance 36 Inspection I II III 36 Checking tightness of rear wheel studs 37 Inspection I 37 RS Check tightness of screws at adjustable handlebar 37 Inspection I 37 R Check steering damper 37 Inspection II III 37 Taking up slac...

Page 11: ...t to initial value 20 20 3 Tighten nut to wrench angle 180 4 Unfasten retighten M10 screw 40 40 Bearing cap on rocker shaft 15 15 Locknut on valve clearance adjusting screw 8 8 Cylinder head cover to cylinder head 8 8 Camshaft end cover to cylinder head 9 9 Air intake connection to cylinder head 9 9 Camshaft Chain sprocket to camshaft 65 65 Camshaft bearing cap 15 15 Rotary breather Vent line to a...

Page 12: ...ine to engine block 35 35 Oil cooler feed line to frame 20 20 Oil cooler feed line to engine block 25 25 Screw in union for oil cooler connection at engine block 35 35 Clean threads and apply Loctite 603 to inner and outer threads and in the contact face area Oil cooler hose at oil thermostat 40 Cylinders Tightening sequence M 8 screw 20 20 M 6 screw 9 9 Chain guide rail pivot screw 18 18 Timing c...

Page 13: ...0 Belt pulley to crankshaft 50 50 Poly V belt preload 8 8 Spark plug 20 20 13 Fuel preparation and control Temperature sensor on engine block 25 25 16 Fuel tank and lines Fuel tank to rear frame 22 22 Fuel pump assembly to tank 6 6 18 Exhaust system Muffler to footrest 35 35 Manifold to cylinder head with strap 22 22 with jacket pipe 18 18 Muffler to support plate for center stand 20 20 Clip on mu...

Page 14: ... plug 23 23 Gearbox cover to gearbox housing 9 9 Screw for neutral detent 13 13 clean thread Loctite 243 Oil guide plate at gearbox housing 9 9 clean thread Loctite 573 also apply Loctite 573 to sealing face between oil baffle plate and gear box housing Gearbox to engine block 22 22 Clutch lever to gearbox housing 18 18 Selector lever to selector shaft 9 9 Pedal to footrest plate 35 18 Model R 110...

Page 15: ...clean thread Loctite 243 Screw plug to fixed fork tube 18 pressed fit do not release Clamping screws quick release axle 22 22 Control arm to engine right 73 73 Screw cap left 42 42 apply light coat of Never Seez to thread Spring strut to frame 47 47 Spring strut to control arm 43 8 8 screw 43 8 8 screw 50 10 9 screw 50 10 9 screw 32 Steering Handlebar at rubber mount 40 Rubber mount at fork bridge...

Page 16: ...wheel drive 150 150 clean thread Loctite 2701 Free bearing journal Swinging arm to gearbox Swinging arm at rear wheel drive 7 7 clean thread Loctite 2701 Locknut on free bearing journal 105 105 clean thread Loctite 2701 Strut at rear wheel drive gearbox 43 43 load motorcycle with approx 85 kg and tighten loose strut Spring strut to rear frame rear swinging arm 43 8 8 screw 43 8 8 screw 50 10 9 scr...

Page 17: ...front brake caliper 7 7 Bleed screw on rear brake caliper 7 4 Master cylinder to footrest plate 9 9 Brake pedal to footrest plate 37 37 Handbrake lever pivot pinl 8 8 the Tuflok blue thread retaining agent can be slackened off and tightened several times if nec essary ABS sensor 4 handtight 4 handtight ABS unit to holder M6 screw 9 9 M6 screw Torx 5 5 Brake line to ABS unit 15 15 Bleed screw to AB...

Page 18: ... to cylinder head 20 20 Side stand to pivot mount 42 42 clean thread Loctite 2701 Center stand to carrier plate 21 21 clean thread Loctite 2701 Carrier plate for center stand to engine block M12 screw 72 72 clean thread Loctite 2701 M 8 screw countersunk 21 21 clean thread Loctite 2701 Grab handle to rear frame 9 9 Lifting handle to rear frame 10 10 Footrest plate to rear frame M 6 screw 9 M 8 scr...

Page 19: ...ction Nm Nm Ignition steering lock to fork bridg 15 15 61 General electrical system Horn to horn bracket 8 20 Ground earth strap to engine block 10 10 Rubber bushing for battery holder at gearbox 4 4 Model R 1100 RS R 1100 RT ...

Page 20: ...n one nut to initial value 20 20 3 Tighten nut to wrench angle 180 4 Unfasten retighten M10 screw 40 40 Bearing cap on rocker shaft 15 15 Locknut on valve clearance adjusting screw 8 8 Cylinder head cover to cylinder head 8 8 Camshaft end cover to cylinder head 9 9 Air intake connection to cylinder head 9 9 Camshaft Chain sprocket to camshaft 65 65 Camshaft bearing cap 15 15 Rotary breather Vent l...

Page 21: ...der 9 9 Oil cooler return line to engine block 35 35 Oil cooler feed line to engine block 25 25 Screw in union for oil cooler connection at engine block 35 35 Clean threads and apply Loctite 603 to inner and outer threads and in the contact face area Cylinders Tightening sequence 1 M 8 screw 20 20 2 M 6 screw 9 9 3 Chain guide rail pivot screw 18 18 Timing chain Chain tensioner 32 32 Connecting ro...

Page 22: ...ey to crankshaft 50 50 Poly V belt preload 8 8 Spark plug 20 20 13 Fuel preparation and control Temperature sensor on engine block 25 25 16 Fuel tank and line Fuel tank to rear frame 22 22 Fuel pump assembly to tank 6 6 Strut to tank 15 18 Exhaust system Muffler to rear frame 24 24 Manifold to cylinder head with strap 22 22 with jacket pipe 18 18 Muffler to support plate for center stand 20 20 Cli...

Page 23: ...ug 23 23 Gearbox cover to gearbox housing 9 9 Screw for neutral detent 13 13 clean thread Loctite 243 Oil guide plate at gearbox housing 9 9 clean thread Loctite 573 also apply Loctite 573 to sealing face between oil baffle plate and gear box housing Gearbox to engine block 22 22 Clutch lever to gearbox housing 18 18 Selector lever to selector shaft 9 9 Pedal to footrest plate 35 35 Model R 850 11...

Page 24: ...o fixed fork tube press fit do not release Clamping screws quick release axle 22 22 Control arm to engine right 73 73 Screw cap left 42 42 apply light coat of Never Seez to thread Spring strut to frame 47 47 Spring strut to control arm 50 10 9 screw 50 10 9 screw Steering damper to fork slider bridge mount 20 clean thread Loctite 2701 Steering damper mount to fork slider bridge 9 clean thread Loct...

Page 25: ...Fixed bearing journal Swinging arm at gearbox Swinging arm at rear wheel drive 150 150 clean thread Loctite 2701 Free bearing journal Swinging arm to gearbox Swinging arm to rear wheel drive 7 7 clean thread Loctite 2701 Locknut on free bearing journal 105 105 clean thread Loctite 2701 Strut at rear wheel drive gearbox 43 43 load motorcycle with approx 85 kg and tighten loose strut Spring strut to...

Page 26: ...o flow distributor 15 15 Flow distributor to frame 9 9 Flow distributor to slider tube bridge 9 Flow distributor to holder slider tube 9 Bleed screw on front brake caliper 7 7 Bleed screw on rear brake caliper 4 4 Master cylinder to footrest plate 9 9 Brake pedal to footrest plate 37 37 Handbrake lever pivot pinl 8 8 the Tuflok blue thread retaining agent can be slackened off and tightened several...

Page 27: ... gearbox Footrest plate to gearbox 22 22 Frame to engine 82 82 Struts to frame 47 8 8 screw 47 8 8 screw 58 10 9 screw 58 10 9 screw Struts to engine 58 58 Guard hoop to cylinder head 20 20 Side stand to pivot mount 42 42 clean thread Loctite 2701 Center stand to carrier plate 21 21 clean thread Loctite 2701 Carrier plate for center stand to engine block M12 screw 72 72 clean thread Loctite 2701 M...

Page 28: ...on Nm Nm Ignition steering lock to fork bridge 15 15 61 General electrical system Horn to horn bracket 8 8 Ground earth strap to engine block 10 10 Rubber bushing for battery holder at gearbox 4 4 Model R 850 1100 GS R 850 1100 R ...

Page 29: ...2 M Permanently elastic sealant 81 22 9 400 339 100 g tube Adhesives and retaining agents Loctite 648 Structural adhesive ultra high speed 07 58 9 067 732 5 g bottle Loctite 638 Joint connector 07 58 9 056 030 10 ml bottle Loctite 243 Thread retainer medium strength 07 58 9 056 031 10 ml bottle Loctite 270 Thread retainer strong 81 22 9 400 086 10 ml bottle Loctite 2701 Thread retainer 33 17 2 331...

Page 30: ...il filter element with oil and screw in Top up oil seal off Do not check oil level until at least 10 minutes af ter test run test ride eCaution Never add engine oil above the MAX mark XTightening torque Oil filter 11 Nm Oil drain plug 32 Nm Fill quantity for engine with oil filter change 3 75 l 6 6 Imp pints without oil filter change 3 50 l 6 2 Imp pints Oil volume between MIN and MAX marks 0 50 l...

Page 31: ...er plug 23 Nm Fill quantity gearbox up to lower rim of filler hole Initial filling 1 0 l 1 76 Imp pints During oil changes 0 8 l 1 4 Imp pints Changing oil in rear wheel drive Unscrew and remove oil filler plug and oil drain plug drain off oil Fit new seal and screw in drain plug Top up gearbox oil Insert oil filler plug with new seal XTightening torque Oil drain plug 23 Nm Oil filler plug 23 Nm F...

Page 32: ...trap 3 Remove battery eCaution Disconnect negative terminal of battery first then positive terminal Connect positive battery terminal first then negative terminal Top up battery acid level with distilled water as far as the MAX mark Installation in reverse order Protective battery post grease e g Bosch Ft 40 V1 XTightening torque Fuel tank to rear frame 22 Nm Renewing air cleaner Inspection III Re...

Page 33: ...er panel 1 at fuel tank GS Remove right side fairing R Remove fuel tank cover RT Detach storage compartment Unfasten fuel tank mount 2 Seal off fuel feed and return line 3 with hose clip BMW No 13 3 010 loosen and pull off Remove vent pipes 4 Remove fuel pump connector 5 Lift off fuel tank RS 1 5 3 4 2 13 3 010 RS160010 ...

Page 34: ...00 26 C A B C A B 6x 6x RT 13 3 010 3 5 4 RT160060 ...

Page 35: ...00 27 e Caution Fuel is flammable and a hazard to health Observe relevant safety regulations Drain fuel tank Remove fuel pump unit detach vent hoses RS000130 ...

Page 36: ... non reusable hose clips with pliers BMW No 13 1 500 eCaution Note correct direction of flow through fuel filter Use only an O ring seal 2 in good condition After assembly check fuel pump unit for leaks XTightening torqu Fuel tank to rear frame 22 Nm Fuel pump unit to fuel tank 6 Nm 1 2 RS160030 ...

Page 37: ...eCaution Trap escaping oil Select a gear and turn the rear wheel or set the piston to TDC by turning the belt pulley Top dead centre on ignition stroke 1 The OT TDC mark appears and 2 the inlet and exhaust valves of the cylinder in question are closed Tighten cylinder head nuts Tightening procedure after 1000 km 600 miles 1 Tighten cylinder head nuts individually in a cross wise pattern 1 1 Slacke...

Page 38: ...mm 0 006 in Exhaust 0 30 mm 0 012 in XTightening torque Locknut 8 Nm Check valve clearance again it must be possible to insert the feeler gauge between valve stem and rocker with only slight resistance to move ment Assemble in reverse order eCaution Make sure that gasket is correctly seated Gaskets and sealing faces must be free from oil or grease XTightening torqu Cover screw 8 Nm Spark plug with...

Page 39: ...procedure Poly V belt installation procedure Place the Poly V belt in position tension it and turn the engine over once then release belt ten sion Poly V belt tensioning procedure Screw hex nut 1 on adjusting screw 2 up handtight no tools to be used Tighten adjusting screw 2 with a torque wrench fully tighten retaining nut 3 slacken adjusting screw and tighten screws fully XTightening torque Poly ...

Page 40: ...ness 1 5 mm 0 059 in Renewing brake pads front brake Unfasten remove brake caliper eCaution RS R RT Do not scratch the wheel rim mask it off with tape if necessary Remove keeper from retaining pin 1 Drive out retaining pin 1 Remove brake pads by pulling downwards Before installing the brake caliper push the pistons back fully with resetting tool BMW No 34 1 500 Install in the reverse order of work...

Page 41: ...e installing the brake caliper depress the piston fully Install in the reverse order of work XTightening torque Brake caliper at rear wheel drive 40 Nm Checking brake discs for wear Carefully inspect brake discs for cracking dam age distortion wear and scoring Brake disc wear limit 4 5 mm 0 177 in RS rear 4 6 mm 0 181 in Checking brake fluid level topping up Inspection III Remove reservoir cover t...

Page 42: ...e cali per and leave the resetting tool in position Apply handbrake lever several times until brake pressure can be detected Maintain pressure on handbrake lever then open bleed screw while maintaining firm pressure on the handbrake lever eCaution Do not release the lever pedal until the bleed screw has been closed Close bleed screw and release handbrake lever Allow brake fluid to emerge from both...

Page 43: ...U 30 PTM Lubricant e g Shell Retinax A RS Cleaning and greasing the windshield adjusting shaft Inspection III Unscrew clean and grease the shaft then screw it back in Lubricant e g Shell Retinax A RS Grease front suspension strut at its lower attachment lug version with plain bearing only Inspection II III Lubricant e g Never Seeze XTightening torque Spring strut to control arm 43 Nm RS000330 RS33...

Page 44: ...mm Allen key BMW No 31 5 600 RT Slacken off the power socket holder Using socket wrench BMW No 21 3 610 slacken off locknut 1 at adjusting screw 2 on the clutch release lever gearbox Set to distance B at the handlebar clutch lever using the adjusting screw on the release lever Distance B 7 0 mm 0 276 in XTightening torque Locknut on adjusting screw 22 Nm A RS210020 1 2 21 3 610 RS210030 B RS210040...

Page 45: ...n hose clips at intake stub pipen Inspection I III XTightening torque Hose clips on air intake pipe 2 Nm Checking front wheel bearings checking tilt play at rear wheel Inspection III Relieve load on front wheel Tilt the front wheel to and fro across the axle No play should be detected If play is detected in the wheel bearings renew them Tilt the rear wheel to and fro across the wheel axle If play ...

Page 46: ...eased idle speed choke Choke cable play 1 mm 0 039 in Adjust the wire cable from the throttle twistgrip when the handlebar is on full right lock Throttle cable play app 0 5 mm 0 0197 in Pre adjust the wire connecting cable between the throttle stub pipes with the left or right ad justing screw Adjust the connecting cable to zero play RS130020 RS130030 RS130040 ...

Page 47: ...and select the bar chart display with maximum resolution L Note If the differences between the individual col umns are very large greater than 5 mm switch to graph display and compare the cylinders carry out fault di agnosis if necessary a See BMW Synchrotester diagnosis instructions Rectify any faults found Set idle speed using recirculating air screws while maintaining synchronous running L Note...

Page 48: ... vacuum bores of the throttles Ride the motorcycle until the engine is warm or alternatively allow it to warm up at a standstill for approx 10 minutes eCaution Engine must not run for more than 20 minutes when motorcycle is not moving Oil temperature at least 90 C FID at least 5 bars Switch on the Synchrotester and select the bar chart with maximum resolution L Note If the differences between the ...

Page 49: ...bar display re verts to its original height Tighten the locknut L Note The height of the bar display must not change when the locknut is tightened Repeat this procedure at the right throttle L Note If play is zero the throttle butterflies may chatter Adjust throttle cable play at screws 1 Push the protective rubber cap 2 back over the adjusting screw Throttle cable play app 0 5 mm 0 0197 in Adjust...

Page 50: ...n closed L Note Make sure that both throttle valves close against their stops when the throttle twistgrip is released Tighten locknuts and check synchronous run ning again Seal the vacuum bores Final inspection with road safety and functional check Inspection I II III IV Road safety check Check wheels and tyres Check correct tyre pressures Tyre pressures Rider only front 2 2 bar 31 9 psi rear 2 5 ...

Page 51: ... Assembly specification for timing chain tensioner 57 Removing valve gear holder 58 Dismantling reassembling valve gear holder 59 Removing cylinder head 61 Dismantling checking repairing and re assembling cylinder head 62 Removing and installing valves 62 Removing valve stem seals 62 Checking valves for wear 63 Remachining valve seat 63 Checking and repairing cylinder head 63 Checking valve guide ...

Page 52: ...rankshaft auxiliary shaft and timing chain tensioning and slide rails 76 Removing and installing oil pick up basket 77 Replacing oil level sight glass 77 Removing conrods 77 Checking conrods 77 Measuring main and big end bearing play 78 easuring radial bearing play 78 Install main bearings 79 Measuring axial bearing play 79 Measuring big end bearing play 80 Assembling engine 81 Installing conrod 8...

Page 53: ...cylinder head 91 Adjusting valve clearances 92 Installing right cylinder head 93 Adjustment specification 93 Installing left cylinder head 94 Adjustment specification 94 Installing alternator mount cover 96 Installing magnetic gate belt pulley 96 Timing the ignition 97 Installing alternator 98 Installing engin 99 ...

Page 54: ...11 4 ...

Page 55: ... 04 below 8 5 123 28 Intake port dia cylinder head mm in 44 1 732 Lubrication system Theoretical volume in circulation at 6000 min 1 Lubricating oil l Imp pints Cooling oil l Imp pints 36 63 36 30 52 8 Oil filter Full flow type Pressure differential needed to open bypass valve bar psi 1 5 21 756 Oil pressure warning light comes on below bar psi 0 2 0 5 2 9 7 25 Pressure relief valve opens at bar p...

Page 56: ... 0 23524 Wear limit mm in 5 940 0 23386 Exhaust mm in 5 945 5 960 0 23406 0 23465 Wear limit mm in 5 925 0 23327 from 1996 mod year on Inlet mm in 4 966 4 980 0 16551 0 19606 Wear limit mm in 4 946 0 19472 Exhaust mm in 4 956 4 970 0 19512 0 19567 Wear limit mm in 4 936 0 19433 Valve head edge thickness Inlet mm in 1 00 0 2 0 03937 0 00787 Wear limit mm in 0 5 0 01969 Exhaust mm in 1 65 0 2 0 0649...

Page 57: ... from 1996 mod year on Inlet mm in 33 4 0 1 1 31496 0 00393 Exhaust mm in 28 4 0 1 1 11811 0 00393 Seat ring dia oversize 0 2 mm Inlet mm in 37 634 37 650 1 48165 1 48228 Exhaust mm in 34 134 34 150 1 34386 1 34449 from 1996 mod year on Inlet mm in 36 617 36 633 1 44161 1 44224 Exhaust mm in 32 134 32 150 1 26512 1 26575 Seat dia in cylinder head oversize 0 2 mm Inlet mm in 37 500 37 525 1 47638 1...

Page 58: ...Exhaust mm in 0 040 0 070 0 001575 0 002756 Wear limit mm in 0 17 0 006693 from 1996 mod year on Valve guide Intl dia mm in 5 0 5 012 0 19685 0 19732 Radial clearance Inlet mm in 0 020 0 046 0 000787 0 001811 Wear limit mm in 0 15 0 00591 Exhaust mm in 0 030 0 056 0 0011811 0 002205 Wear limit mm in 0 17 0 006693 Valve spring Spring length off load mm in 41 1 1 61811 Wear limit mm in 39 0 1 53543 ...

Page 59: ... in 15 92 15 95 0 62677 0 62795 Width of camshaft bearing mm in 16 0 16 05 0 62992 0 6318897 Axial play mm in 0 08 0 13 0 0031496 0 005118 Wear limit mm in 0 25 0 0098425 Bucket type tappet Extl dia mm in 23 947 23 960 0 942795 0 9433 Bore dia in cylinder head mm in 24 000 24 021 0 94488 0 94571 Radial clearance mm in 0 040 0 074 0 00175 0 002913 Wear limit mm in 0 18 0 0070866 Auxiliary shaft Bor...

Page 60: ...9 2 16528 2 16689 Yellow 55 008 55 049 2 16567 2 16728 Main bearing journal dia mm in Green 54 971 54 980 2 1642 2 164567 Yellow 54 981 54 990 2 16461 2 16496 Radial clearance mm in 0 018 0 068 0 0001086 002677 Wear limit mm in 0 13 0 005118 Width of guide bearing mm in 24 890 24 940 0 97992 0 98189 Bearing width of main bearing journal mm in 25 020 25 053 0 98504 0 986339 Axial play mm in 0 080 0...

Page 61: ...12 0 0047244 Permitted out of roundness of cylinder bore 20 mm from the top edge mm in 0 03 0 0011811 100 mm from the lower edge mm in 0 04 0 0015748 Pistons Piston dia Measuring plane A a see Checking pistons and cylinders A mm in 98 965 98 977 3 89626 3 896732 Wear limit mm in 98 890 3 8933 B mm in 98 977 98 989 3 896732 3 897204 Wear limit mm in 98 900 3 8937 AB mm in 98 973 98 981 3 89657 3 89...

Page 62: ...arance mm in 0 030 0 065 0 00118 0 002559 Wear limit mm in 0 15 0 00591 3rd groove Equal chamfer ring tubular spring Height mm in 2 475 2 490 0 09744 0 09803 Wear limit mm in 2 4 0 094488 Gap clearance mm in 0 30 0 60 0 011811 0 023622 Wear limit mm in 1 20 0 047244 Side clearance mm in 0 020 0 055 0 000787 0 002165 Wear limit mm in 0 15 0 00591 Installed direction of piston rings Top marking uppe...

Page 63: ...5 04 below 8 5 123 28 Intake port dia cylinder head mm in 44 1 732 Lubrication system Theoretical vol in circulation at 6000 min 1 Lubricating oil l Imp pints Cooling oil l Imp pints 36 63 36 30 52 8 Oil filter Full flow type Pressure differential needed to open bypass valve bar psi 1 5 21 756 Oil pressure warning light comes on below bar psi 0 2 0 5 2 9 7 25 Pressure relief valve opens at bar psi...

Page 64: ... 23465 0 23524 Wear limit mm in 5 940 0 23386 Exhaust mm in 5 945 5 960 0 23406 0 23465 Wear limit mm in 5 925 0 23327 from 1996 mod year on Inlet mm in 4 966 4 980 0 16551 0 19606 Wear limit mm in 4 946 0 19472 Exhaust mm in 4 956 4 970 0 19512 0 19567 Wear limit mm in 4 936 0 19433 Valve head edge thickness Inlet mm in 1 00 0 2 0 03937 0 00787 Wear limit mm in 0 5 0 01969 Exhaust mm in 1 65 0 2 ...

Page 65: ... 0 00591 Wear limit mm in 2 5 0 09843 Exhaust mm in 1 4 0 15 0 05512 0 00591 Wear limit mm in 3 0 0 11811 Valve seat extl dia dimension for valve seat machining Inlet mm in 35 2 0 1 1 38583 0 003937 Exhaust mm in 30 3 0 1 1 19291 0 00393 from 1996 mod year on Inlet mm in 33 4 0 1 1 31496 0 00393 Exhaust mm in 28 4 0 1 1 11811 0 00393 Seat ring dia oversize 0 2 mm Inlet mm in 37 634 37 650 1 48165 ...

Page 66: ...Exhaust mm in 0 040 0 070 0 001575 0 002756 Wear limit mm in 0 17 0 006693 from 1996 mod year on Valve guide Intl dia mm in 5 0 5 012 0 19685 0 19732 Radial clearance Inlet mm in 0 020 0 046 0 000787 0 001811 Wear limit mm in 0 15 0 00591 Exhaust mm in 0 030 0 056 0 0011811 0 002205 Wear limit mm in 0 17 0 006693 Valve spring Spring length off load mm in 41 1 1 61811 Wear limit mm in 39 0 1 53543 ...

Page 67: ...aring mm in 15 92 15 95 0 62677 0 62795 Width of camshaft bearing mm in 16 0 16 05 0 62992 0 6318897 Axial play mm in 0 08 0 13 0 0031496 0 005118 Wear limit mm in 0 25 0 0098425 Bucket type tappet Extl dia mm in 23 947 23 960 Bore dia in cylinder head mm in 24 000 24 021 0 94488 0 94571 Radial clearance mm in 0 040 0 074 0 00175 0 002913 Wear limit mm in 0 18 0 0070866 Auxiliary shaft Bore dia in...

Page 68: ...3937 Main bearing bore dia mm in 60 000 60 019 2 3622 2 36295 Main bearing dia mm in Green 54 998 55 039 2 16528 2 16689 Yellow 55 008 55 049 2 16567 2 16728 Main bearing journal dia mm in Green 54 971 54 980 2 1642 2 164567 Yellow 54 981 54 990 2 16461 2 16496 Radial clearance mm in 0 018 0 068 0 0001086 002677 Wear limit mm in 0 13 0 005118 Width of guide bearing mm in 24 890 24 940 0 97992 0 98...

Page 69: ...027559 Cylinders Bore 20mm 0 7874 in from top edge A mm in 98 992 99 000 3 89732 3 897638 Wear limit mm in 99 050 3 899606 B mm in 99 000 99 008 3 897638 3 897953 Wear limit mm in 99 058 3 899921 Total wear clearance of piston and cylinder mm in 0 12 0 0047244 Permitted out of roundness of cylinder bore 20 mm from the top edge mm in 0 03 0 0011811 100 mm from the lower edge mm in 0 04 0 0015748 Pi...

Page 70: ...in 1 175 1 190 0 04626 0 04685 Wear limit mm in 1 1 0 043307 Gap clearance mm in 0 1 0 3 0 003937 0 0118 Wear limit mm in 0 8 0 031496 Side clearance mm in 0 030 0 065 0 00118 0 002559 Wear limit mm in 0 15 0 00591 3rd groove Equal chamfer ring tubular spring Height mm in 2 475 2 490 0 09744 0 09803 Wear limit mm in 2 4 0 094488 Gap clearance mm in 0 30 0 60 0 011811 0 023622 Wear limit mm in 1 20...

Page 71: ...2 44 1 732 Lubrication system Theoretical vol in circulation at 6000 min 1 Lubricating oil l Imp pints Cooling oil l Imp pints 36 63 36 30 52 8 36 63 36 30 52 8 Oil filter Full flow type Full flow type Pressure differential needed to open bypass valve bar psi 1 5 21 756 1 5 21 756 Oil pressure warning light comes on below bar psi 0 2 0 5 2 9 7 25 0 2 0 5 2 9 7 25 Pressure relief valve opens at bar...

Page 72: ...5 0 23524 Wear limit mm in 4 946 0 19472 5 940 0 23386 Exhaust mm in 4 956 4 970 0 19512 0 19567 5 945 5 960 0 23406 0 23465 Wear limit mm in 4 936 0 19433 5 925 0 23327 from 1996 mod year on Inlet mm in 4 966 4 980 0 16551 0 19606 Wear limit mm in 4 946 0 19472 Exhaust mm in 4 956 4 970 0 19512 0 19567 Wear limit mm in 4 936 0 19433 Valve head edge thickness Inlet mm in 1 00 0 2 0 03937 0 00787 1...

Page 73: ...3 from 1996 mod year on Inlet mm in 33 4 0 1 1 31496 0 00393 Exhaust mm in 28 4 0 1 1 11811 0 00393 Seat ring dia oversize 0 2 mm Inlet mm in 34 634 34 650 1 36254 1 36417 37 634 37 650 1 48165 1 48228 Exhaust mm in 30 134 30 150 1 186378 1 18701 34 134 34 150 1 34386 1 34449 from 1996 mod year on Inlet mm in 36 617 36 633 1 44161 1 44224 Exhaust mm in 32 134 32 150 1 26512 1 26575 Seat dia in cyl...

Page 74: ...0591 Exhaust mm in 0 030 0 056 0 0011811 0 002205 0 040 0 070 0 001575 0 002756 Wear limit mm in 0 17 0 006693 0 17 0 006693 from 1996 mod year on Valve guide Intl dia mm in 5 0 5 012 0 19685 0 19732 Radial clearance Inlet mm in 0 020 0 046 0 000787 0 001811 Wear limit mm in 0 15 0 00591 Exhaust mm in 0 030 0 056 0 0011811 0 002205 Wear limit mm in 0 17 0 006693 Valve spring Spring length off load...

Page 75: ...95 0 62677 0 62795 Width of camshaft bearing mm in 16 0 16 05 0 62992 0 6318897 16 0 16 05 0 62992 0 6318897 Axial play mm in 0 08 0 13 0 0031496 0 005118 0 08 0 13 0 0031496 0 005118 Wear limit mm in 0 25 0 0098425 0 25 0 0098425 Bucket type tappet Extl dia mm in 23 947 23 960 23 947 23 960 Bore dia in cylinder head mm in 24 000 24 021 0 94488 0 94571 24 000 24 021 0 94488 0 94571 Radial clearanc...

Page 76: ...95 60 000 60 019 2 3622 2 36295 Main bearing dia mm in Green 54 998 55 039 2 16528 2 16689 Green 54 998 55 039 2 16528 2 16689 Yellow 55 008 55 049 2 16567 2 16728 Yellow 55 008 55 049 2 16567 2 16728 Main bearing journal dia mm in Green 54 971 54 980 2 1642 2 164567 Green 54 971 54 980 2 1642 2 164567 Yellow 54 981 54 990 2 16461 2 16496 Yellow 54 981 54 990 2 16461 2 16496 Radial clearance mm in...

Page 77: ...om top edge 20 mm 0 7874 in from top edge A mm in 87 492 87 500 3 444567 3 44489 98 992 99 000 3 89732 3 897638 Wear limit mm in 87 550 3 44685 99 050 3 899606 B mm in 87 500 87 508 3 44489 3 4452 99 000 99 008 3 897638 3 897953 Wear limit mm in 87 558 3 447165 99 058 3 899921 Total wear clearance of piston and cylinder mm in 0 12 0 0047244 0 12 0 0047244 Permitted out of roundness of cylinder bor...

Page 78: ...175 1 190 0 04626 0 04685 Wear limit mm in 1 1 0 043307 1 1 0 043307 Gap clearance mm in 0 3 0 5 0 0118 0 019685 0 1 0 3 0 003937 0 0118 Wear limit mm in 1 00 0 03937 0 8 0 031496 Side clearance mm in 0 030 0 070 0 00118 0 0027559 0 030 0 065 0 00118 0 002559 Wear limit mm in 0 15 0 00591 0 15 0 00591 3rd groove Equal chamfer ring tubular spring Height mm in 2 475 2 490 0 09744 0 09803 2 475 2 490...

Page 79: ...44 1 732 Lubrication system Theoretical volume in circulation at 6000 min 1 Lubricating oil l Imp pints Cooling oil l Imp pints 36 63 36 30 52 8 36 63 36 30 52 8 Oil filter Full flow type Full flow type Pressure differential needed to open bypass valve bar psi 1 5 21 756 1 5 21 756 Oil pressure warning light comes on below bar psi 0 2 0 5 2 9 7 25 0 2 0 5 2 9 7 25 Pressure relief valve opens at ba...

Page 80: ... 23465 0 23524 Wear limit mm in 4 946 0 19472 5 940 0 23386 Exhaust mm in 4 956 4 970 0 19512 0 19567 5 945 5 960 0 23406 0 23465 Wear limit mm in 4 936 0 19433 5 925 0 23327 ab Mj 96 Inlet mm in 4 966 4 980 0 16551 0 19606 Wear limit mm in 4 946 0 19472 Exhaust mm in 4 956 4 970 0 19512 0 19567 Wear limit mm in 4 936 0 19433 Valve head edge thickness Inlet mm in 1 00 0 2 0 03937 0 00787 1 00 0 2 ...

Page 81: ...93 from 1996 mod year on Inlet mm in 33 4 0 1 1 31496 0 00393 Exhaust mm in 28 4 0 1 1 11811 0 00393 Seat ring dia oversize 0 2 mm Inlet mm in 34 634 34 650 1 36254 1 36417 37 634 37 650 1 48165 1 48228 Exhaust mm in 30 134 30 150 1 186378 1 18701 34 134 34 150 1 34386 1 34449 from 1996 mod year on Inlet mm in 36 617 36 633 1 44161 1 44224 Exhaust mm in 32 134 32 150 1 26512 1 26575 Seat dia in cy...

Page 82: ...00591 Exhaust mm in 0 030 0 056 0 0011811 0 002205 0 040 0 070 0 001575 0 002756 Wear limit mm in 0 17 0 006693 0 17 0 006693 from 1996 mod year on Valve guide Intl dia mm in 5 0 5 012 0 19685 0 19732 Radial clearancel Inlet mm in 0 020 0 046 0 000787 0 001811 Wear limit mm in 0 15 0 00591 Exhaust mm in 0 030 0 056 0 0011811 0 002205 Wear limit mm in 0 17 0 006693 Valve spring Spring length off lo...

Page 83: ... 95 0 62677 0 62795 Width of camshaft bearing mm in 16 0 16 05 0 62992 0 6318897 16 0 16 05 0 62992 0 6318897 Axial play mm in 0 08 0 13 0 0031496 0 005118 0 08 0 13 0 0031496 0 005118 Wear limit mm in 0 25 0 0098425 0 25 0 0098425 Bucket type tappet Extl dia mm in 23 947 23 960 23 947 23 960 Bore dia in cylinder head mm in 24 000 24 021 0 94488 0 94571 24 000 24 021 0 94488 0 94571 Radial clearan...

Page 84: ...295 60 000 60 019 2 3622 2 36295 Main bearing dia mm in Green 54 998 55 039 2 16528 2 16689 Green 54 998 55 039 2 16528 2 16689 Yellow 55 008 55 049 2 16567 2 16728 Yellow 55 008 55 049 2 16567 2 16728 Main bearing journal dia mm in Green 54 971 54 980 2 1642 2 164567 Green 54 971 54 980 2 1642 2 164567 Yellow 54 981 54 990 2 16461 2 16496 Yellow 54 981 54 990 2 16461 2 16496 Radial clearance mm i...

Page 85: ...rom top edge 20 mm 0 7874 in from top edge A mm in 87 492 87 500 3 444567 3 44489 98 992 99 000 3 89732 3 897638 Wear limit mm in 87 550 3 44685 99 050 3 899606 B mm in 87 500 87 508 3 44489 3 4452 99 000 99 008 3 897638 3 897953 Wear limit mm in 87 558 3 447165 99 058 3 899921 Total wear clearance of piston and cylinder mm in 0 12 0 0047244 0 12 0 0047244 Permitted out of roundness of cylinder bo...

Page 86: ... 175 1 190 0 04626 0 04685 Wear limit mm in 1 1 0 043307 1 1 0 043307 Gap clearance mm in 0 3 0 5 0 0118 0 019685 0 1 0 3 0 003937 0 0118 Wear limit mm in 1 00 0 03937 0 8 0 031496 Side clearance mm in 0 030 0 070 0 00118 0 0027559 0 030 0 065 0 00118 0 002559 Wear limit mm in 0 15 0 00591 0 15 0 00591 3rd groove Equal chamfer ring tubular spring Height mm in 2 475 2 490 0 09744 0 09803 2 475 2 49...

Page 87: ...11 37 Sectioned drawing of engine RS119010 ...

Page 88: ...11 38 Lubricating oil circuit RS119020 ...

Page 89: ...11 39 Coolant circuit RS119030 ...

Page 90: ...11 40 Cooling oil circuit with oil thermostat RT119010 ...

Page 91: ...t can only be dismantled after the engine has been removed All other components can be dismantled while the engine is still installed Drain engine oil RT Remove lower section of fairing Attach stand BMW No 00 1 520 to motorcycle GS Use extension bushings and bolts BMW No 00 1 527 GS 00 1 520 RS110520 ...

Page 92: ...l 1 at fuel tank R Unscrew fuel tank cover RT Detach storage compartment from tank Unfasten fuel tank mount 2 Seal loosen and pull off fuel feed and return line 3 with hose clip BMW No 13 3 010 Remove vent pipes 4 Remove connector at fuel pump 5 Remove fuel tank 2 5 1 3 4 13 3 010 RS RS160010 ...

Page 93: ...11 43 C A B C A B 6x 6x RT 13 3 010 3 5 4 RT160060 ...

Page 94: ...ipe 2 Remove battery 3 eCaution Disconnect negative terminal first then positive terminal Remove Motronic control unit Remove spark plug covers Pull off spark plug caps with puller BMW No 12 3 520 RS 1 2 3 GS R RT RS000340 RS130010 12 3 520 RS120170 ...

Page 95: ... Retain brake lines with cable straps eCaution Always follow the instructions in the repair manua a See Group 34 Removing and installing ABS unit ABS Detach brake pipes at gearbox RT Detach brake master cylinder RS340010 RS110530 ...

Page 96: ...ble guide under bat tery holder Separate connector Hall effect transmitter wire 1 Separate connector oxygen sensor 2 Pull off plug NTC oil temperature 3 Detach leads from alternator RS GS RT Detach starter motor cover pull off socket cable Detach leads on starter motor remove starter motor RS460010 RS610010 RS610020 1 2 3 RS110540 RS110510 RS120141 ...

Page 97: ...11 47 Disconnect oil pressure switch 1 Separate plug connection for side stand switch 2 Separate plug connection for gearbox neutral indicator switch 3 Detach ground earth strap 4 2 4 3 1 RS610044 ...

Page 98: ...11 48 RS Version without rotary breather Detach oil return line at oil trap 1 Detach engine breather pipe from engine 2 2 1 RS110570 ...

Page 99: ...ht oil cooler line from engine 2 R Detach oil cooler holder and remove together with oil cooler Unscrew hose clips throttle stub pipe and insert stub pipe into air cleaner box Remove rear brake caliper tie up to rear frame with cable strap ABS GS R RT Detach ABS sensor Disconnect clutch cable RT 2 1 3 RS110561 ...

Page 100: ...11 50 Remove muffler silencer Remove manifold pipes eCaution Detach oxygen sensor cable do not subject to tension GS R RS180040 ...

Page 101: ...11 51 Remove covers 1 on leading link pivots Unfasten left screw cap 2 Remove right retaining ring 3 Remove retaining cap 4 Take out bolt 5 at right 1 3 4 5 2 1 RS310011 ...

Page 102: ...nk mount with adhesive tape to prevent scratching Unfasten rear frame screw connection 5 at front left right Insert adapter 6 into the leading link rear frame mount and secure it to the auxiliary frame Unfasten lower front suspension strut mount Press front of leading link down arrow or pull rear section downwards Unscrew and remove pin 7 securing the frame to the engine e Caution Protect tank mou...

Page 103: ...der head and pull downwards Apply a light coating of grease to the leading link shaft insert from the left and secure tightly Unfasten lower front suspension strut mount Press front of leading link downwards or pull rear section downwards Using mandrel BMW No 46 5 630 align the front frame bores with the engine bore from the left insert the pin from the right and screw up tightly eCaution Do not s...

Page 104: ...antling engine Attach engine mount BMW No 11 0 630 to engine block Transfer engine to assembly frame Drain engine oil Remove oil filter using oil filter wrench BMW No 11 4 650 11 0 630 RS110010 11 4 650 RS110950 ...

Page 105: ...11 55 Removing cylinder head cover Unscrew and remove spark plugs with spark plug wrench BMW No 12 3 510 Remove cylinder head cover eCaution Trap escaping oil 12 3 510 RS110020 ...

Page 106: ... TDC mark is visible and 2 the inlet and exhaust valves in the cylinder in question are closed Secure the clutch housing with locking device BMW No 11 5 640 L Note The engine can be set to top dead center with the TDC pin BMW No 11 2 650 which is inserted into the clutch housing and the engine block at TDC RS 11 003 TDC 11 5 640 RS110030 11 2 650 TDC RS110461 ...

Page 107: ...n for timing chain ten sioner Removal Remove timing chain tensioner then remove cam shaft sprocket from camshaft Installation First install camshaft sprocket then timing chain tensioner eCaution Failure to observe this sequence can cause the chain tensioner piston to fall into the left side of the timing chain cavity XTightening torque Chain tensioner 32 Nm RS110060 ...

Page 108: ...not removed after loosening it must be held firmly and prevented from falling into the engine block e g with a cable strap Remove valve gear holder Secure rockers with a rubber band 2 L Note If no work is carried out on the valve gear holder re move it together with the cylinder head 1 2 M6 x 30 M6 x 30 M6 x 30 M6 x 60 RS110070 RS110051 ...

Page 109: ...bearing cap Insert a suitable drift into the bore arrow of the rocker shaft and pull the shaft out of the mount by twisting it in both directions Remove pushrods eCaution Do not accidentally confuse rocker shafts and pushrods M8 x 40 M8 x 30 M8 x 40 RS110080 ...

Page 110: ... The cutout on the rocker shafts must be aligned with the retaining holes L Note Locate pushrods in ball cups on rockers and hold the rockers together with a rubber band to secure the pushrods in position XTightening torque M 8 screw in rocker shaft bearing cap 15 Nm M 8 screw for camshaft bearing cap 15 Nm Reposition the bearings until minimum endplay is obtained End float of rocker min 0 05 mm 0...

Page 111: ...11 61 Removing cylinder head M6 x 30 M6 x 30 M6 x 30 M10 x 70 RS110110 ...

Page 112: ...ioner BMW No 11 5 690 to cylinder head Clamp the valve springs Separate valve collet from spring plate by striking the valve head gently Remove valve collet sections Relieve tension on valve springs Remove top bottom spring plates valve springs and valves Removing valve stem seals Pull off valve stem seal with pliers BMW No 11 1 250 L Note If a valve is removed the valve stem seal must be renewed ...

Page 113: ...always be maintained when remachining the valve seat a See Technical Data Checking and repairing cylinder head Remove combustion residues from combusion chamber Check sealing face for damage distortion and skim flat if necessary Skimming sealing face max 0 2 mm 0 00787 in metal re moval Checking valve guide for wear Check valve guide bore a See Technical Data B D RS110890 ...

Page 114: ...damaged or not to correct dimensions Determine actual diameter of valve guide using micrometer Open out bore with Ø12 7 H7 mm 12 700 12 718 mm 0 5 0 50071 in reamer Repair method 2 lathe turn the valve guide bore must not be damaged Determine actual diameter of bore with internal measuring tool Calculate the nominal diameter of the valve guide Nominal diameter of valve guide bore dia inter ference...

Page 115: ... stem Install the valve stem seal with a 6 5 mm 0 236 0 197 in dia drift BMW No 11 5 601 602 eCaution Remove the assembly sleeve and the shrink fit tube Fit lower spring plate valve spring and upper spring plate Compress the valve springs with the clamping tool BMW No 11 5 690 L Note Insert the taper valve collets using grease to simpli fy assembly eCaution Ensure that valve collets are correctly ...

Page 116: ...der ensure that the piston does not strike the engine block Removing dismantling piston Remove both retaining rings on piston pin Press out piston pin by hand Remove piston Carefully remove piston rings with piston ring pli ers Remove carbonized oil from base of piston clean the piston eCaution Do not accidentally confuse pistons piston pins or piston rings 1 RS110170 ...

Page 117: ... Determine piston ring clearance using feeler gauge a See Technical Data Assemble pistons Carefully fit piston rings to piston in the following sequence using piston ring pliers 3rd grooveEqual chamfer ring 2nd groove Micro taper compression ring M ring R 850 m Ø TOP 4 DZ 1st groove Micro taper compression ring B ring R 850 SPT TOP Determine top runout of piston rings a See Technical Data eCaution...

Page 118: ...ft removed eCaution Do not accidentally confuse conrods or bearing shells Install conrods Installed direction of conrods lettering facing up e Caution Oil the bearings Screw the big end bolts in by hand then tighten with an angle indicating wrench BMW No 11 2 500 eCaution Use big end bolts once only XTightening torque Big end bolts oiled Joint torque 20 Nm Wrench angle 80 11 2 500 11 5 640 TDC RS1...

Page 119: ...d RS GS R Remove starter motor cover Remove starter motor Remove rear leading link mount Removing alternator mount cover Remove alternator Remove rotary breather line 1 Lock clutch housing with retaining device BMW No 11 5 640 Remove pulley 2 Remove magnetic gate 3 L Note If complete alternator mount cover is re moved leave magnetic gate 3 installed Remove alternator mount cover 4 4 3 1 11 5 640 2...

Page 120: ...Note Slide new radial shaft seal over taper on slid ing sleeve pre shape and pull off Renewing radial shaft seal for rotary breather Carefully lever radial shaft seal out using a screwdriver Carefully pre form the lip of the radial shaft seal by hand Drive in the new radial shaft seal oiled lightly us ing handle BMW No 00 5 550 and drift BMW No 11 5 650 11 5 680 RS110240 00 5 550 11 5 650 RS110241...

Page 121: ...ipe forwards Remove chain tensioner 2 Remove chain tensioning rail 3 Remove chain guide rail 4 Lock the clutch housing with retaining device BMW No 11 5 640 Unscrew and remove chain sprocket retaining bolt 5 Remove rotor 6 with chain sprocket 7 and timing chain 8 If necessary remove chain sprocket 9 2 3 8 9 5 7 1 4 11 5 640 6 RS1100251 RS110961 ...

Page 122: ... with cooling oil pipe 3 and dismantle eCaution Check installed positions of parts which have already been run together Oil temperature regulator Expanding element 1 L Note Do not dismantle the oil temperature regulator 3 1 2 M6 x 50 M6 x 45 M6 x 45 M6 x 50 M6 x 45 RS110410 1 RT110580 ...

Page 123: ...ing with retaining device BMW No 11 5 640 Remove clutch Carefully lever radial shaft seal out using a screwdriver e Caution Avoid damaging the sealing faces on the housing and the crankshaft L Note When dismantling the crankcase the radial seal can be taken out 11 5 640 RS210010 RS110270 ...

Page 124: ...11 74 Dismantling crankcase Turn engine on to its side Remove screws on right side M10 x 100 M8 x 80 M8 x 35 M10 x 100 M8 x 80 M8 x 35 RS110261 ...

Page 125: ...ove screws on left side Remove upper section of crankcase M6 x 50 M6 x 25 M6 x 35 M6 x 50 M10 x 100 M6 x 25 M6 x 50 M6 x 25 M6 x 35 M6 x 35 M10 x 100 M6 x 50 M6 x 35 M6 x 35 M6 x 35 M6 x 50 M6 x 50 M6 x 50 M6 x 50 M6 x 35 M6 x 50 RS110260 ...

Page 126: ...11 76 Removing crankshaft auxiliary shaft and timing chain tensioning and slide rails RS110290 ...

Page 127: ...river and lever out the oil level sight glass Coat the sealing face of the new oil level sight glass with engine oil and drive it in with drift BMW No 00 5 550 Removing conrods Clamp crankshaft in a vise provided with protec tive jaws Remove conrod eCaution Do not accidentally confuse the conrods Checking conrods Check conrod dimensions a See Technical Data eCaution Sintered metal conrods must nev...

Page 128: ... Enter measured values on record sheet a See Technical Data eCaution The crankshaft can only be reground in grinding stage 0 after this it must be rehardened and finished Grinding stages are identified by a paint mark on the front crank web a See Technical Data If the bearing shells have to be replaced note colored marks on crankpins and big end bearings RS110310 ...

Page 129: ...values on record sheet and determine main bearing play values a See Technical Data Measuring axial bearing play Place crankshaft in engine block Insert tensioning rail slide rail pivot pin 1 for centering purposes Tighten housing screws Screw measuring device BMW No 00 2 500 with dial gauge BMW No 00 2 510 in the tapped hole for the alternator mount cover Move crankshaft forwards and backwards and...

Page 130: ...ssemble conrods Tighten big end bolt with tightening angle indicator BMW No 11 2 210 XTightening torque Big end bolts oiled Joint torque 20 Nm Wrench angle 80 Measure big end bearing with internal gauge in thrust direction Enter measured values on record sheet and determine big end bearing clearances a See Technical Data RS110340 11 2 210 RS110350 RS110360 ...

Page 131: ...d in by hand and tighten with tightening angle indicator BMW No 11 2 210 eCaution Oil the bearings Do not accidentally confuse conrods or bearing shells Always use new big end bolts Installed direction of conrods lettering facing up XTightening torque Big end bolts oiled Joint torque 20 Nm Wrench angle 80 11 2 210 RS110370 ...

Page 132: ... pin for tensioning rail slide rail at clutch side arrow with 3 Bond 1209 Insert pivot screw 1 into chain tensioner rail us ing a new sea XTightening torqu Chain guide rail pivot pin 18 Nm Installing auxiliary shaft timing chains eCaution Timing chains 2 must mesh fully with auxiliary shaft sprockets 1 u 2 RS110291 ...

Page 133: ... faces arrow with 3 Bond 1209 Secure the timing chain with rubber band 1 to the timing chain tensioning and slide rail M6x50 M6x25 M6x35 M10x100 M6x50 M6x25 M6x35 M6x35 M6x50 M6x50 M10x100 M6x50 M6x35 M6x35 M6x35 M6x50 M6x35 M6x50 M6x50 M6x50 M6x25 1 u RS110920 ...

Page 134: ...11 84 Bolt the crankcase sections together Tightening torque tightening sequence 1 M10 screw oiled 45 Nm 2 M 8 screw oiled 20 Nm 3 M 6 screw 9 Nm M10x100 M8x80 M8x35 M10x100 M8x80 M8x35 RS110391 ...

Page 135: ...ft seal carefuilly by hand 1 Oil the radial shaft seal at the sealing contact surface Place radial seal over sliding sleeve 2 remove sliding sleeve 3 Drive radial shaft seal in with handle BMW No 00 0 500 and drift with sliding sleeve BMW No 11 5 660 4 2 3 4 1 11 5 660 RS110400 ...

Page 136: ...stall clutch housing with mark 1 aligned with crankshaft mark 2 Lock clutch housing with retaining device BMW No 11 5 640 Insert all screws by hand and tighten down XTightening torque Clutch housing to crankshaft screw threads oiled 40 Nm Additional wrench angle 32 1 2 11 5 640 RS210011 ...

Page 137: ...il pipe 2 eCaution O ring 3 must be in good condition Install Woodruff key 4 outer rotor 5 and inner rotor 6 in cooling oil pump Screw housing cover 7 on to oil pump eCaution Note different lengths of screw XTightening torque M 6 screw 9 Nm Pressure relief valve 35 Nm Oil pressure switch 30 Nm 1 2 3 5 6 7 4 M6 x 45 M6 x 45 M6 x 45 M6 x 50 M6 x 50 RS110411 ...

Page 138: ... 10 Nm Install drive shaft chain with chainwheel 2 and rotor 3 XTightening torque Retaining screw at chainwheel 70 Nm Install secure chain guide rail 4 Install secure chain tensioner rail 5 Install chain tensioner housing 6 with piston and spring XTightening torque M 6 screw 9 Nm Tighten down cooling oil line 7 eCaution Use a new sealing ring XTightening torque M 6 screw 10 Nm Banjo screw for cool...

Page 139: ... Ensure that retaining rings are properly seated on piston pin Oil the sliding contact faces Always use pistons of the same weight class in any one engine Markings or a See Technical Data eCaution Always install pistons and cylinders in pairs Do not accidentally confuse pistons or piston pins Piston size identificatio On piston crown A B AB for either A or B cylinder and on cylinder A B X RS110430...

Page 140: ...05 compress the pis ton rings Install the cylinder and at the same time pass the timing chain and the tensioning and guide rail through the timing case cavity Tighten cylinder down firmly Fit new seal to pivot pin for chain guide rail 1 Install chain sprocket Tightening torque tightening sequence 1 M 8 screw 20 Nm 2 M 6 screw 9 Nm 3 Pivot screw for chain guide rail 18 Nm u 11 2 900 1 RS110420 ...

Page 141: ...der head nuts crosswise 1 Unfasten one nut 2 Tighten one nut to initial value 20 Nm 3 Tighten nut to wrench angle 180 4 Unfasten retighten M10 screw 40 Nm Fit camshaft chain sprocket in accordance with adjustment specification Lock clutch housing with retaining device BMW No 11 5 640 Tighten camshaft chain sprocket XTightening torque Camshaft sprocket retaining screw 65 Nm Insert the left side cam...

Page 142: ...learance with adjusting screw and lock into position Valve clearances with engine cold max 35 C Inlet 0 15 mm 0 0059 in Exhaust 0 30 mm 0 0118 in XTightening torque Locknut 8 Nm Check valve clearance again it must be possible to insert the feeler gauge between valve stem and rocker with only slight resistance to move ment RS110980 ...

Page 143: ...et crankshaft are aligned Locate ignition stroke TDC with insert pin BMW No 11 2 650 at hole in clutch housing and en gine block Right cylinder at TDC on ignition stroke Locating pin arrow on right camshaft sprocket points downwards Mark R or arrow and tip of tooth on right camshaft sprocket is precisely aligned with mark X on timing gear carrier Check setting again with timing chain tensioner ins...

Page 144: ...t crankshaft point downwards Locate ignition stroke TDC with insert pin BMW No 11 2 650 at hole in clutch housing and in engine block Left cylinder at TDC on ignition stroke Locating pin arrow on left camshaft sprocket points upwards Mark R or arrow and tip of tooth at left camshaft sprocket is aligned precisely with mark X on timing gear carrier Check setting again with timing chain tensioner ins...

Page 145: ...sitioning the bearings Rocker end float min 0 05 mm 0 00197 in max 0 40 mm 0 0157 in Install cylinder head cover eCaution Ensure that gaskets are properly seated Gaskets and sealing face must be free from oil and grease XTightening torque Cover screw 8 Nm Tighten air intake stub pipe XTightening torque M 6 screw 9 Nm RS110050 RS110100 RS110940 RS110440 ...

Page 146: ...ing device BMW No 11 5 640 from 1995 model year on Prevent rotor 2 of Hall effect gate from moving with for example Loctite instant adhesive at Poly V belt pulley 3 Install the Poly V belt pulley eCaution Install the belt pulley lock 4 from model year 1995 on rotor location at Hall effect gate at the groove crankshaft 5 XTightening torque Retaining screw for belt pulley 50 Nm Install rotary breath...

Page 147: ...W No 11 2 650 Connect ignition tester BMW No 12 3 650 and adapter lead BMW No 12 3 652 to magnetic gate Turn the Hall effect gate plate until the telltale lamp just goes out Tighten plate on Hall effect trigger Remove the TDC insert pin 11 2 650 TDC RS110461 12 3 650 12 3 652 RS110460 ...

Page 148: ...belt tension Poly V belt tensioning procedure Screw up hex nut 1 at adjusting screw 2 lightly by hand using no tools Tighten adjusting screw 2 with a torque wrench fully tighten retaining nut 3 slacken adjusting screw and tighten screws fully XTightening torque Pre tension Poly V belt with adjusting screw 8 Nm Alternatorto alternator support cover 20 Nm Install front cover 1 2 3 RS110480 RS110490 ...

Page 149: ...g with a new seal XTightening torque Oil filter sealing face lightly oiled 11 Nm Oil drain plug 32 Nm Install spark plugs with spark plug wrench BMW No 12 3 510 XTightening torque Spark plug 20 Nm Installing engin Work in reverse order to that stated for removal 11 4 650 RS110950 12 3 510 RS000010 ...

Page 150: ...dure for Poly V belt 9 Dismantling reassembling alternator 10 Checking alternator 11 Checking armature for short to ground earth 11 Removing and installing starter motor 12 Dismantling reassembling starter motor 13 Renewing carbon brushes 13 Checking starter motor 13 Checking starter relay 13 Removing and installing magnetic gate 14 Timing the ignition 15 12 Engine electrics ...

Page 151: ...12 2 ...

Page 152: ... Max operating speed min 1 20 000 Aluminum Poly V belt pulley Extl dia measured at tips of teeth Wear dimension mm in Spark plug Bosch FR 6 DDC Electrode gap mm in 0 8 0 0315 Wear limit mm in 1 0 0 0394 Thread metric M 14 x 1 25 Ignition Ignition system Motronic mapped characteristic control Ignition trigger Two magnetic gates Hall effect transmitters driven from crankshaft Ignition timing KW 0 43...

Page 153: ...ax operating speed min 1 20 000 Aluminum Poly V belt pulley Extl dia measured at tips of teeth Wear dimension mm in Spark plug Bosch FR 6 DDC Electrode gap mm in 0 8 0 0315 Wear limit mm in 1 0 0 0394 Thread metric M 14 x 1 25 Ignition Ignition system Motronic mapped characteristic control Ignition trigger Two magnetic gates Hall effect transmitters driven from crankshaft Ignition timing KW 0 43 b...

Page 154: ...d min 1 20 000 20 000 Aluminum Poly V belt pulley Extl dia measured at tips of teeth Wear dimension mm in 55 5 2 185 Spark plug Bosch FR 6 DDC FR 6 DDC Electrode gap mm in 0 8 0 0315 0 8 0 0315 Wear limit mm in 1 0 0 0394 1 0 0 0394 Thread metric M 14 x 1 25 M 14 x 1 25 Ignition Ignition system Motronic mapped characteristic control Ignition trigger Two magnetic gates Hall effect transmitters driv...

Page 155: ...1 20 000 20 000 Aluminum Poly V belt pulley Extl dia measured at tips of teeth Wear dimension mm in 55 5 2 185 55 5 2 185 Spark plug Bosch FR 6 DDC FR 6 DDC Electrode gap mm in 0 8 0 0315 0 8 0 0315 Wear limit mm in 1 0 0 0394 1 0 0 0394 Thread metric M 14 x 1 25 M 14 x 1 25 Ignition Ignition system Motronic mapped characteristic control Ignition trigger Two magnetic gates Hall effect transmitters...

Page 156: ...nt pipes Separate plug for fuel pump Remove fuel tank e Caution Switch off ignition Disconnect ground earth cable at battery and insulate it GS R Detach Motronic control unit and pull it out upwards Remove ignition coil 1 Separate plug connector 2 Pull off ignition lead 3 Remove spark plug cover 4 Remove plug cap 5 with puller BMW No 12 3 520 Remove ignition lead Install in the reverse order of wo...

Page 157: ...return line with hose clip BMW No 13 0 010 Remove vent pipes Separate plug for fuel pump Remove fuel tank Remove Motronic control unit ABS detach pressure modulator Remove front cover from engine Detach connecting leads 1 from alternator Loosen Poly V belt pulley at alternator Unscrew alternator mount 2 Take off Poly V belt pulley and belt Remove strut 3 from frame at left Remove alternator e Caut...

Page 158: ...nt 1 2 3 Screw up hex nut 1 at adjusting screw 4 lightly by hand using no tools Tighten adjusting screw 4 using torque wrench fully tighten retaining nut 3 slacken off adjusting screw and tighten down screws L Note Siehe auch Serviceinformation 12 020 95 700 XTightening torque Poly V belt preload 8 Nm Alternatorto alternator support cover 20 Nm Positive lead to alternator 15 Nm Belt pulley at alte...

Page 159: ... tor Take out the cover retaining screws 1 Release clips 2 and remove the cover Remove voltage regulator 3 Remove the Poly V belt pulley Install in the reverse order of work XTightening torque Belt pulley at alternator 50 Nm 3 2 1 RS120050 ...

Page 160: ...gative green leads together Ω key is to be pressed until the dig ital display reads 0 00 Ω Using BMW Diagnosis tester BMW No 61 1 510 measure resistance between the sliprings Nominal resistance 3 Ω Checking armature for short to ground earth Measure resistance between sliprings and arma ture Measured result OL open line RS120070 OL RS120060 ...

Page 161: ... ground earth lead RS GS R Remove cover 1 for starter motor and pull off wire 2 for power socket Detach connecting lead 3 Take out retaining screws 4 and remove the starter motor Install in the reverse order of work XTightening torque Starter motor to engine 20 Nm Starter motor cover to gearbox housing 7 Nm Positive lead to starter motor 10 Nm 1 2 4 4 3 RS120140 ...

Page 162: ...ining plate Slide short lead 15 on to threaded pin Install cover 11 Attach lead 1 Checking starter motor Engine temperature 20 C Ammeter in positive lead to starter motor Starter is in good working order at app 80 150 A Voltmeter connected to and on starter mo tor Starter is in good working order at app 10 11 V Checking starter relay L Note Before each Ω measurement calibrate to zero with the BMW ...

Page 163: ...int place foam rubber mat or similar item under tank e Caution Disconnect ground earth lead from battery Insulate the ground earth lead Separate plug connection 1 for magnetic trig ger Remove front cover from engine Slacken off alternator mount 2 and relieve tension on Poly V belt RS GS R Remove starter motor cover pull off power socket lead Remove starter motor Lock clutch housing with retaining ...

Page 164: ...ankshaft 7 Carefully dismantle magnetic trigger lead Tension Poly V belt according to installation procedure XTightening torque Pre tension of Poly V belt 8 Nm Alternatorto alternator mount cover 20 Nm Belt pulley to crankshaft 50 Nm Timing the ignition Lock the clutch housing with the TDC insert pin BMW No 11 2 650 Connect ignition tester BMW No 12 3 650 and adapter lead BMW No 12 3 652 to Hall e...

Page 165: ... 13 Technical Data 3 Removing and installing air cleaner 7 Removing and installing throttle stub pipe 8 Removing and installing injectors 9 Removing and installing Motronic control unit 9 13 Fuel preparation and control ...

Page 166: ...13 2 ...

Page 167: ...cal Data R 1100 RS Fuel grade Super premium unleaded 95 octane RON Mixture preparation Motronic MA 2 2 Throttle stub pipe intl dia mm in 45 1 772 Throttle angle in rest position 10 Air cleaner Circular paper element ...

Page 168: ...al Data R 1100 RT Fuel grade Super premium unleaded 95 octane RON Mixture preparation Motronic MA 2 2 Throttle stub pipe intl dia mm in 45 1 772 Throttle angle in rest position 10 Air cleaner Circular paper element ...

Page 169: ...um un leaded 95 octane RON Super premium unleaded 95 octane RON Mixture preparation Motronic MA 2 2 Motronic MA 2 2 Throttle stub pipe intl dia mm in 45 1 772 45 1 772 Throttle angle in rest position 10 10 Air cleaner Circular paper element Circular paper element ...

Page 170: ...m un leaded 95 octane RON Super premium unleaded 95 octane RON Mixture preparation Motronic MA 2 2 Motronic MA 2 2 Throttle stub pipe intl dia mm in 45 1 772 45 1 772 Throttle angle in rest position 10 10 Air cleaner Circular paper element Circular paper element ...

Page 171: ...m air cleaner box Separate connector between neutral switch and side stand switch and detach lead Unfasten intake pipe from throttle body Motorcycles with throttle cable divider disen gage throttle cables Remove rear muffler silencer ABS Detach brake caliper ABS GS R RT Detach ABS sensor Remove rear wheel Remove suspension strut e Caution Place support under rear wheel drive Unfasten screw connect...

Page 172: ...nfasten retainer 3 for fuel pipe and pull off the pipe Slacken off hose clips Slide intake connection into air cleaner box and remove throttle body e Caution Make sure that the O ring 4 at the throttle stub pipe is in good condition Disconnect throttle cable 5 from the right then from the left throttle body Motorcycle with throttle cable divider a Figure A Disconnect cable 6 for choke Install in t...

Page 173: ...Remove injector e Caution Make sure that O rings at injector are in good con dition Install in the reverse order of work Removing and installing Motronic control unit Remove fuel tank e Caution Switch off ignition disconnect ground earth lead at battery and insulate it Remove Motronic control unit Remove connector strip Install in the reverse order of work RS130010 ...

Page 174: ...ng and installing fuel filter fuel pump and fuel level sensor 9 Removing and installing fuel filter 10 Removing and installing fuel pump and fuel level sensor 10 Checking fuel pump pressure 11 Removing and installing fuel distributor and pressure regulator 11 16 Fuel tank and lines ...

Page 175: ...16 2 ...

Page 176: ...R 1100 RS Fuel tank Tank capacity l Imp pints 23 40 48 including reserve of l Imp pints 6 10 56 Fuel pump Type Gear type Make VDO Operating voltage V 12 Fuel pressure bar psi 3 43 512 Delivery volume l h Imp pints h 110 193 6 ...

Page 177: ...1100 RT Fuel tank Tank capacity l Imp pints 26 45 75 including reserve of l Imp pints 6 10 56 Fuel pump Type Gear type Make VDO Operating voltage V 12 Fuel pressure bar psi 3 43 512 Delivery volume l h Imp pints h 110 193 6 ...

Page 178: ...ank capacity l Imp pints 25 44 25 44 including reserve of l Imp pints 6 10 56 6 10 56 Fuel pump Type Gear type Gear type Make VDO VDO Operating voltage V 12 12 Fuel pressure bar psi 3 43 512 3 43 512 Delivery volume l h Imp pints h 110 193 6 110 193 6 ...

Page 179: ...capacity l Imp pints 21 36 96 21 36 95 including reserve of l Imp pints 6 10 56 6 10 56 Fuel pump Type Gear type Gear type Make VDO VDO Operating voltage V 12 12 Fuel pressure bar psi 3 43 512 3 43 512 Delivery volume l h Imp pints h 110 193 6 110 193 6 ...

Page 180: ...k R Remove fuel tank cover Remove fuel tank retaining screw 2 Seal loosen and pull off fuel feed and return line 3 with hose clip BMW No 13 3 010 Remove vent pipes 4 Separate plug connector 5 for fuel pump Lift off fuel tank Install in the reverse order of work XTightening torque Fuel tank to rear frame 22 Nm RS 13 3 010 1 2 5 3 4 RS160010 ...

Page 181: ...16 8 C A B C A B 6x 6x RT 13 3 010 3 5 4 RT160060 ...

Page 182: ...and installing fuel filter fuel pump and fuel level sensor eCaution Fuel is flammable and a hazard to health Observe relevant safety regulations Drain fuel tank Remove fuel pump unit 1 and detach hoses 2 1 2 RS160020 ...

Page 183: ...Unfasten electrical connections 2 at fuel pump 3 Unscrew hose clip 4 Remove fuel pump Install in the reverse order of work Tighten non reusable hose clips with special pliers BMW No 13 1 500 eCaution Use only an O ring 5 in good condition After assembly check fuel pump unit for leaks XTightening torque Fuel pump assembly to tank 6 Nm 1 3 4 5 2 RS160030 ...

Page 184: ...t idle speed Fuel pressure Nominal value 3 bar 43 51 psi L Note If fuel pressure is low check pump fuel filter pressure regulator and fuel line Removing and installing fuel distrib utor and pressure regulator Remove air cleaner box a See Group 23 Removing gearbox Pressure regulator 1 16 1 500 RS160040 1 RS160050 ...

Page 185: ...18 1 Contents Page 18 Removing and installing exhaust system 3 Removing and installing muffler silencer 3 Removing and installing front exhaust pipes 4 18 Exhaust system ...

Page 186: ...18 2 ...

Page 187: ...ount GS R Unscrew the rear pipe clip Remove rear muffler Install in the reverse order of work eCaution Note position of wiring for oxygen sensor XTightening torque RS RT Muffler to footrest 35 Nm GS R Muffler at rear frame 24 Nm Muffler to support plate for center stand 20 Nm Clip on muffler Grease clamping surface with Never Seeze 50 Nm CAT Remove and install oxygen sensor 5 eCaution After trial ...

Page 188: ... front exhaust pipes Install in the reverse order of work L Note When installing use new seals 7 XTightening torque Front exhaust pipes with plate at cylinder head 22 Nm Front exhaust pipes with outer pipe at cylinder head 18 Nm Clip at muffler coat clamping surface with Never Seez 50 Nm 6 7 7 6 2 RS180030 ...

Page 189: ...21 1 Contents Page 21 Technical Data 3 Removing and installing clutch 7 Removing clutch 9 Installing clutch 9 Adjusting clutch operating clear ance 10 21 Clutch ...

Page 190: ...21 2 ...

Page 191: ...gh hollow gearbox shaft Clutch plate dia mm in 180 7 0879 Wear dimension mm in 4 5 0 177 measured on rivets of clutch plate using tips of sliding caliper pressed together by hand Manual effort required Nm 65 Clutch operating clearance at handlebar lever mm in 7 0 276 Distance for basic clutch adjustment free thread length at adjusting screw on handlebar lever mm in 12 0 472 ...

Page 192: ... hollow gearbox shaft Clutch plate dia mm in 180 7 0879 Wear dimension mm in 4 5 0 177 measured on rivets of clutch plate using tips of sliding caliper pressed together by hand Manual effort required Nm 65 Clutch operating clearance at handlebar lever mm in 7 0 276 Distance for basic clutch adjustment free thread length at adjusting screw on handlebar lever mm in 12 0 472 ...

Page 193: ...shaft Clutch plate dia mm in 180 7 0879 180 7 0879 Wear dimension mm in 4 5 0 177 4 5 0 177 measured on rivets of clutch plate using tips of sliding caliper pressed together by hand Manual effort required Nm 65 65 Clutch operating clearance at handlebar lever mm in 7 0 276 7 0 276 Distance for basic clutch adjustment free thread length at adjusting screw on handlebar lever mm in 12 0 472 12 0 472 ...

Page 194: ...haft Clutch plate dia mm in 180 7 0879 180 7 0879 Wear dimension mm in 4 5 0 177 4 5 0 177 measured on rivets of clutch plate using tips of sliding caliper pressed together by hand Manual effort required Nm 65 65 Clutch operating clearance at handlebar lever mm in 7 0 276 7 0 276 Distance for basic clutch adjustment free thread length at adjusting screw on handlebar lever mm in 12 0 472 12 0 472 ...

Page 195: ... the air cleaner housing Remove front rear air cleaner box Remove muffler Unfasten plug connector for neutral switch and side stand switch detach leads Disconnect plug for brake light switch and de tach lead ABS GS R RT Detach the plug connection at the rear sensor line and the line itself Remove brake fluid reservoir from holder Remove rear brake pipe from holder Unfasten screw connection on rear...

Page 196: ...Locate the gearbox when removing and installing with oiled guide pins BMW No 23 1 820 Remove rear wheel rear wheel drive unit and swinging arm together with gearbox eCaution Hold gearbox at installation height until entire clutch push rod is visible or else this may be bent Install in the reverse order of work 23 1 820 23 1 820 RS230011 ...

Page 197: ...ew threads lightly Initial tightening 40 Nm Wrench angle 32 Install clutch e Caution Offset the color marks on the clutch housing driven plate and housing cover through 120 in each case Secure clutch with retaining screws 4 Center the clutch plate with centering pin BMW No 21 3 680 Tighten retaining screws alternately in a cross wise pattern Lubrication points Splines on clutch plate and input sha...

Page 198: ...en key BMW No 31 5 600 RT If necessary detach the power socket holder Using socket wrench BMW No 21 3 610 loosen locknut 1 for adjusting screw 2 at clutch release lever Set to distance B at the handlebar lever by turn ing adjusting screw 2 on the clutch release le ver Distance B 7 mm 0 276 in XTightening torque Locknut on adjusting screw 22 Nm A RS210020 21 3 610 2 1 RS210030 B RS210040 ...

Page 199: ... and installing detent lever 17 Removing and installing shift pawls 17 Removing and installing torsion spring 17 Removing and installing selector shaft seal 17 Removing deep groove ball bearing from selector drum 18 Shimming selector drum 18 Removing taper roller bearing race from input shaft and roller bearing from idler shaft 18 Installing deep groove ball bearing on selector drum 19 Installing ...

Page 200: ...ctor drum 32 Shimming gearbox shafts 33 Measuring shaft bearing play 33 Measuring gearbox cover 34 Shimming the gearbox shafts without Clean Bearing 35 Example 35 Shimming the gearbox shafts with Clean Bearing 35 Example 35 Removing and installing taper roller bearing race 36 Checking friction coefficient of input shaft taper roller bearing 36 Installing gearbox cover 37 Removing and installing in...

Page 201: ...pints 1 0 1 76 to lower edge of filler screw When oil is changed l Imp pints approx 0 8 1 408 to lower edge of filler screw End float on idler shaft mm in 0 05 0 15 0 00196 0 0059 End float on output shaft mm in 0 05 0 15 0 00196 0 0059 End float input shaft Clean Bearing mm in 0 05 0 15 0 00196 0 0059 Preload on input shaft 0 2 mm 0 00787 0 5 1 0 Nm frictio End float at selector drum deep groove ...

Page 202: ... changed l Imp pints approx 0 8 1 408 to lower edge of filler screw End float on idler shaft mm in 0 05 0 15 0 00196 0 0059 End float on output shaft mm in 0 05 0 15 0 00196 0 0059 End float input shaft Clean Bearing mm in 0 05 0 15 0 00196 0 0059 Preload on input shaft 0 2 mm 0 00787 0 5 1 0 Nm frictio End float at selector drum deep groove ball bearing mm in 0 1 0 0039 End float at deep groove b...

Page 203: ... approx 0 8 1 408 to lower edge of filler screw approx 0 8 1 408 to lower edge of filler screw End float on idler shaft mm in 0 05 0 15 0 00196 0 0059 0 05 0 15 0 00196 0 0059 End float on output shaft mm in 0 05 0 15 0 00196 0 0059 0 05 0 15 0 00196 0 0059 End float input shaft Clean Bearing mm in 0 05 0 15 0 00196 0 0059 0 05 0 15 0 00196 0 0059 Preload on input shaft 0 2 mm 0 00787 0 5 1 0 Nm f...

Page 204: ... screw End float on idler shaft mm in 0 05 0 15 0 00196 0 0059 0 05 0 15 0 00196 0 0059 End float on output shaft mm in 0 05 0 15 0 00196 0 0059 0 05 0 15 0 00196 0 0059 End float input shaft Clean Bearing mm in 0 05 0 15 0 00196 0 0059 0 05 0 15 0 00196 0 0059 Preload on input shaft 0 2 mm 0 00787 0 5 1 0 Nm frictio 0 2 mm 0 00787 0 5 1 0 Nm frictio End float at selector drum deep groove ball bea...

Page 205: ...23 7 Gearbox sectioned drawing RS239010 ...

Page 206: ...23 8 ...

Page 207: ...ging arm and drive shaft heat pivot pin to max 120 C remove Disconnect clutch cable from release lever Remove release lever 1 Unscrew clip 2 Remove sleeve and spring 3 4 Remove clutch piston 5 Withdraw clutch thrust rod 6 Lubricating points arrow Optimoly MP3 compound Install in the reverse order of work L Note Check adjust clutch operating clearance L Note Check clutch release bearing at piston 5...

Page 208: ...l tank Remove battery eCaution Disconnect the negative battery terminal first then the positive terminal Connect the positive battery terminal first then the negative terminal Motorcycles with throttle cable divider release Bowden cable divider Unscrew rear battery mount Remove plug from air temperature sensor Remove air cleaner cover Detach air intake pipe and push it into the air cleaner box Unf...

Page 209: ... wheel Remove rear wheel drive unit Remove swinging arm heat pivot pin to max 120 C and remove Press off drive shaft Unfasten fuel line from injector and remove Remove cable connector wiring harness from air cleaner box Detach return line oil trap from air cleaner box Remove air cleaner box Disconnect clutch cable from gearbox RS GS R Detach starter motor cover and pull off wire to power socket De...

Page 210: ...ove retaining ring 3 from selector drum Unfasten retaining screw on clutch lever 4 Unfasten hose clip 5 Remove sleeve 6 coil spring 7 and clutch piston 8 Replacing shaft seal on neutral switch Remove shaft seal using a suitable tool Using light fingertip pressure insert the shaft seal fully Direction of installation spring facing oil chamber 23 1 610 4 6 5 7 8 1 2 3 R230020 ...

Page 211: ... from gearbox cover Heat gearbox cover to 100 C at the bearing seats Place sliding sleeve BMW No 23 4 632 on the input shaft Press off gearbox cover evenly Remove ball 3 from neutral stop Remove spacers 5 oil baffle plate 6 eCaution Do not accidentally confuse spacers 23 4 632 4 2 1 3 6 5 j 100 Clean Bearing RT230032 ...

Page 212: ...rbox housing Turn selector forks outwards Position pawl 2 opposite recess in selector drum L Note Avoid damage to rollers 4 on guide pins of selector forks Withdraw selector drum 3 turning it slightly at the same time Remove selector forks 1 3 4 2 Clean Bearing RT230041 ...

Page 213: ...ding sleeve 3 BMW No 23 4 622 on output shaft 1993 model year Pull the idler and output shaft 4 out of the gearbox housing together from 1994 model year on Pull the input idler and output shaft out of the gearbox housing to gether Removing and installing input shaft sealing ring at housing end Force shaft seal inwards using drift Drive in the sealing ring with a drift and guide sleeve BMW No 23 4 ...

Page 214: ...23 16 Removing dismantling reassembling selector shaft Remove selector shaft 1 Attach sliding sleeve 2 BMW No 23 4 612 and pull out selector shaft with washer 3 23 4 612 2 1 3 RS230060 ...

Page 215: ...5 and spring from pawl holder Removing and installing torsion spring Remove retaining ring 6 Remove torsion spring 7 with washers Removing and installing selector shaft seal Remove bearing bushing 1 from sliding seat Force out shaft seal with drift working from the inside Drive in the seal with drift BMW No 23 4 611 Install bearing bushing 1 4 3 5 6 7 RS230071 2 23 4 611 1 RS230100 ...

Page 216: ...lay 0 1 mm 0 0039 in If necessary use a wider retaining ring to elimi nate play Removing taper roller bearing race from input shaft and roller bearing from idler shaft Heat gearbox housing to 100 C Depending on tolerance the bearing races may already slide out of their seat when the housing is heated Pull out taper roller bearing race if necessary us ing counter support BMW No 00 8 562 and interna...

Page 217: ...Installing taper roller bearing race on input shaft and roller bearing for idler shaft Heat gearbox housing to 100 C Insert roller bearing with drift BMW No 23 4 660 and handle BMW No 00 5 500 Insert taper roller bearing race with drift BMW No 23 4 670 and handle BMW No 00 5 500 eCaution Bearing must be firmly located Note different diam eters of taper roller bearing outer races on input shaft 23 ...

Page 218: ...off deep groove ball bearing or race roller bearing with universal puller BMW No 00 7 500 To install deep groove ball bearing or race roller bearing heat to 80 C and push into position eCaution If necessary drive further on by striking inner race only eCaution Be careful of the sealing washer as you heat the bearing Clean Bearing risk of damage 00 7 500 RS230181 ...

Page 219: ...1 Using a universal puller BMW No 00 7 500 and pressure head arrow pull off spur gear 3 together with taper roller bearing 2 Remove washer 6 coil spring 5 pressure piece 4 and spur gear 3 Pull off the taper roller bearing 7 in the same way Slide on washer 6 with chamfer facing the end away from the spring Slide coil spring 5 pressure piece 4 and spur gear 3 onto shaft 6 7 5 4 1 2 3 RS230150 00 7 5...

Page 220: ...aring Fit universal puller under spur gear and press ta per roller bearing firmly against retaining ring eCaution To prevent measuring errors when installing shims later zero backlash is required between bearing and retaining ring Using a press press on taper roller bearing 7 cold or heat it to 80 C and position it on the input shaft L Note If the input shaft has to be shimmed again do not in stal...

Page 221: ...and GAn 100 23 0 08 3 946 0 00315 install a 42x52x1 25 1 65x2 05x0 049 washer for each If DAn 39 5 0 1 1 555 0 00393 and GAn 99 0 0 1 3 898 0 00393 do not install 42x52x1 25 1 65x2 05x0 049 washers 42 x 52 x 1 25 42 x 52 x 1 25 20 x 28 x 0 5 42 x 52 x 0 30 42 x 52 x 0 35 42 x 52 x 0 40 42 x 52 x 0 45 42 x 52 x 0 50 42 x 52 x 0 55 20 x 1 75 20 x 1 85 20 x 1 95 25 x 52 x 15 20 x 52 x 15 7 5 4 1 3 2 ...

Page 222: ...ear and seat bearing against locking ring eCaution In order to avoid measuring errors when shims are subsequently installed make sure that there is no clearance between bearing and locking ring Press on grooved ball bearing 8 cold using press or heat to 80 C 176 F and position on input shaft eCaution If necessary drive further on by striking inner race only eCaution Be careful of the sealing washe...

Page 223: ... sary adjust distance G with shims from 1994 model year Measurement and ad justment of G are no longer needed Removing deep groove ball bearing Clamp the output shaft into a vise with soft jaws Using universal puller BMW No 00 7 500 and pressure head pull off the deep groove ball bearing 1 G 125 8 0 1 RS230191 00 7 500 RS230192 ...

Page 224: ... model year on take off the O ring 15 Remove spacer 7 and bearing bushing 6 with spur gear for 4th gear 8 Remove retaining ring 9 Remove toothed disk 10 Remove spur gear for 2nd gear 11 Remove split needle cage 12 Remove toothed disk 13 and retaining ring 14 from 1994 model year on Take off O ring 16 1 6 15 7 8 3 4 5 2 RS230193 3 4 5 RS230194 16 14 13 12 11 10 9 RS230195 ...

Page 225: ... jaws the drive shaft splines must face upwards Slide spur gear for 3rd gear 5 onto output shaft with apertures facing upwards Fit thrust washer Heat the wide race 3 to 80 C and push it onto the output shaft as far as the support washer Fit spur gear for 5th gear 2 with dogs facing downwards Fit thrust washer Press on grooved ball bearing cold using press or heat to 80 C and position on input shaf...

Page 226: ...e output shaft as far as the spacing washer from 1994 model year on Heat the narrow race 6 to 80 C and push it on flush with the step in the shaft Slide spur gear for 1st gear 1 onto output shaft with aperture and shift teeth facing downwards Fit thrust washer Press on grooved ball bearing cold using press or heat to 80 C and position on input shaft eCaution If necessary drive further on by striki...

Page 227: ...nsert the input idler and output shafts into the gearbox housing to gether With gentle blows of a plastic faced hammer check that bearing is firmly seated eCaution Do not strike the seat of a Clean Bearing shaft as otherwise the bearing might no longer be correctly seated on the locking ring Install oil baffle plates 4 eCaution After installation of the oil baffle plates turn the gears and check f...

Page 228: ...23 30 Removing and installing output shaft seal Force out shaft seal with drift working from the inside Drive in the new shaft seal with drift and sliding sleeve BMW No 23 4 620 23 4 620 RS230210 ...

Page 229: ...2 RT GS Attach gear shift pedal 1 horizontally making sure that distance A is correct Distance A 51 9 1 8 mm 2 043 0 07 mm RS R Attach gear shift pedal 1 horizontal not ing distance B Maß B 61 2 1 8 mm 2 409 0 07 mm XTightening torque Gear shift pedal 9 Nm 23 4 612 23 4 612 2 1 RS230230 A 1 RT230330 B 1 RS230340 ...

Page 230: ... central guide in top of output shaft Install selector fork 4 for 3rd and 4th gears in idler shaft with short end of guide pointing down wards Installing selector drum Swing the selector forks over to the edge of the housing Install selector drum with its recess facing the selector shaft pawl 5 L Note If necessary secure needle rollers with grease Insert selector fork guide pins into selector drum...

Page 231: ...of its seat then measure without delay eCaution Do not strike the seat of a Clean Bearing shaft as otherwise the bearing might no longer be correctly seated on the locking ring Measure distance between measuring plate and bearing collar on input shaft Enter all measurements in a table a see page 23 28 Key to abbreviations used in measurements MAb Dimension between measuring plate and output shaft ...

Page 232: ...r bearing with oil baffle plate removed The oil baffle plate is slightly corrugated which can falsify the measurement Key to abbreviations used in measurements DAb Cover dimension output shaft DZw Cover dimension idler shaft DAn Cover dimension input shaft Enter all measurements in a table a see page 23 28 Clean Bearing RT230261 DAn DZw DAb RS230270 DAn DZw DAb Clean Bearing RT230271 ...

Page 233: ...e without spacers specified end float 0 05 0 15 mm 0 00196 0 0059 in 0 05 0 15 mm 0 00196 0 0059 in permitted preload 0 20 mm 0 00787 in thickness of spacers Shimming the gearbox shafts with Clean Bearing Example Dimensions in millimeters Output shaft Ab Idler shaft Zw Input shaft An H 60 00 mm 2 362 in 60 00 mm 2 362 in 60 00 mm 2 362 in M measure G D measure G Clearance without shims and input s...

Page 234: ...ift BMW No 23 4 670 and handle BMW No 00 5 500 insert the bearing race in the gearbox cover while it is still hot Checking friction coefficient of input shaft taper roller bearing Install gearbox cover XTightening torque Retaining screws 10 Nm Using adapter BMW No 23 3 670 and friction meter BMW No 00 2 570 check friction in the input shaft taper roller bearing by turning at app 1 revolution per s...

Page 235: ...x cover to 100 o C Fit gearbox cover insert selector shaft and selec tor drum in bearings Preload arm of stop lever spring attach and completely fit gearbox cover eCaution Arm of spring at clutch end of gearbox housing must be under preload and must not be dis placed to wards the output end of housing Tighten down gearbox cover Insert idle stop 3 ball and spring into gearbox Insert the neutral det...

Page 236: ...oving and installing input shaft seal at housing cover end Drive out shaft sealing ring with punch from the inside Drive in the new sealing ring with a drift and sliding sleeve BMW No 23 4 630 23 4 630 RS230290 ...

Page 237: ...ose clip 6 Install clutch lever 7 Install thrust rod 8 XTightening torque Retaining screw on clutch lever 18 Nm Lubrication points Splines on clutch plate and input shaft Diaphragm spring contact face at clutch housing iaphragm spring contact face at driven plate Release lever adjusting screw contact face at clutch piston Lubricant Optimoly MP3 paste Oil fill quantity to lower edge of filler screw...

Page 238: ...h centering pin BMW No 21 3 680 Screw in guide pins oiled BMW No 23 1 820 and push the gearbox carefully on to them XTightening torque Gearbox to engine block 22 Nm Installation is performed in the reverse order to the removal procedure 23 1 820 23 1 820 RS230011 ...

Page 239: ...t 11 RS Checking ball joint friction 11 GS R RT Checking ball joint ball thrust bearing friction 11 Assembly specification for telescopic fork 12 Dismantling reassembling telescopic fork 13 Dismantling telescopic fork 13 Assembling telescopic fork 14 Measuring telescopic fork 14 Check slider tube bridge 14 Checking runout of fixed tube 14 Removing and installing leading link 15 Dismantling reassem...

Page 240: ...31 2 ...

Page 241: ...ing lock angle 32 Total suspension travel mm in 120 4 7244 Fixed tube surface Hard chrome plate Extl dia of fixed fork tubes mm in 35 0 1 3779 Maximum permissible runout of fixed fork tube mm in 0 4 0 01574 Telescopic fork oil approved grades BMW telescopic fork oil Fill quantity in each fork leg l Imp pints 0 470 0 827 Suspension strut Type Suspension strut with coil spring and twin tube gas fill...

Page 242: ...ng lock angle 34 Total suspension travel mm in 120 4 7244 Fixed tube surface Hard chrome plated Extl dia of fixed fork tubes mm in 35 0 1 3779 Maximum permissible runout of fixed fork tube mm in 0 4 0 01574 Telescopic fork oil approved grades BMW telescopic fork oi Fill quantity in each fork leg l Imp pints 0 470 0 827 Suspension strut Type Suspension strut with coil spring and twin tube gas fille...

Page 243: ...on travel mm in 190 190 Fixed tube surface Hard chrome plated Hard chrome plated Extl dia of fixed fork tubes mm in 35 0 1 3779 35 0 1 3779 Maximum permissible runout of fixed fork tube mm in 0 4 0 01574 0 4 0 01574 Telescopic fork oil approved grades BMW telescopic fork oil BMW telescopic fork oil Fill quantity in each fork leg l Imp pints 0 470 0 827 0 470 0 827 Suspension strut Type Suspension ...

Page 244: ...on travel mm in 120 4 7244 120 4 7244 Fixed tube surface Hard chrome plated Hard chrome plated Extl dia of fixed fork tubes mm in 35 0 1 3779 35 0 1 3779 Maximum permissible runout of fixed fork tube mm in 0 4 0 01574 0 4 0 01574 Telescopic fork oil approved grades BMW telescopic fork oil BMW telescopic fork oil Fill quantity in each fork leg l Imp pints 0 470 0 827 0 470 0 827 Suspension strut Ty...

Page 245: ...fork out downwards Install in the reverse order of work Tighten ball joint at leading arm with socket wrench insert and internal hexagon BMW No 31 5 600 on leading link eCaution To prevent grease from escaping and the ingress of dirt ensure that sleeve is correctly located on ball joint ABS Check sensor gap and adjust if necessary ABS Sensor gap 0 50 0 55 mm 0 0197 0 0217 in XTightening torque Bal...

Page 246: ...0 Nm GS R RT Removing and installing fork bridge Unscrew fuel tank and pull to the rear Separate connecting plug for ignition steering lock Detach handlebar from fork bridge Unfasten fixed tube screw connection at fork bridge preventing movement by holding hexa gon on fixed tube Unfasten screw connection between fork bridge and frame L Note Screw pin is a press fit in ball thrust bearing remove co...

Page 247: ... Remove top snap ring 2 Press out pot type joint using drift and bushing BMW No 31 5 660 Snap ring 3 is installed Press in pot type joint using drift BMW No 31 5 661 Install snap ring 2 Install dust covers 1 31 5 661 31 5 662 1 1 2 GS310080 31 5 661 1 2 1 3 GS310090 ...

Page 248: ...ut the threaded journal using a pin BMW No 31 5 651 as a support Press the threaded journal into the ball thrust bearing using a pin BMW No 31 5 651 as a support Heat the fork bridge to 100 C and press the ball thrust bearing in with pin BMW No 31 5 651 and bushing BMW No 31 5 653 Install retaining ring 1 j 100 w GS310100 31 5 651 GS310110 31 5 651 GS310120 31 5 651 31 5 653 j 100 w GS310130 ...

Page 249: ...an thread Loctite 243 22 Nm Ball joint on control arm clean thread Loctite 2701 130 Nm Removing and installing ball joint Mount the slider tube bridge in retaining fixture BMW No 31 5 620 Unscrew tighten ball joint with 46 mm 1 811in socket wrench insert BMW No 31 5 630 XTightening torque Ball joint to fork slider bridge 230 Nm RS Checking ball joint friction GS R RT Checking ball joint ball thrus...

Page 250: ...tube bridge to leading link XTightening torque Leading link at ball joint clean thread Loctite 2701 130 Nm Using a strap or similar pull fork towards frame until the fully retracted fixed tubes only need to be pulled out slightly to secure them to the fork bridge Secure fixed tubes to the fork bridge Secure fixed tubes to the fork bridge XTightening torque Clamp between fixed tubes and fork bridge...

Page 251: ...Dismantling telescopic fork Remove bleed screw 1 Remove drain plug 2 drain oil Remove fixed tube Remove dust cover 3 retaining ring 4 Lever out shaft seal 5 eCaution Do not damage fork slider tube Remove washer 6 1 2 3 4 5 6 7 GS R RT RS 1 GS310050 ...

Page 252: ...apter BMW No 31 5 613 Install retaining ring and dust cover Insert bleed screw 1 Bleed telescopic fork in no load position XTightening torque RS Threaded plug at fixed tube 18 Nm GS R RT Threaded plug at fixed tube press fit do not remove Measuring telescopic fork eCaution After an accident always examine the telescopic fork for cracks and signs of damage Check slider tube bridge Check that the sl...

Page 253: ...in the reverse order of work Apply a light coating of grease to the axle before installing Using socket wrench insert and Allen key BMW No 31 5 600 tighten the ball joint at the leading link RS Coat the lower suspension strut mount with Never Seez L Note Only applies to plain bearings XTightening torque Right control arm on engine 73 Nm Left screw cap coat thread lightly with Never Seez 42 Nm Lead...

Page 254: ... contact with piston rod end of thread lock ball head against nut eCaution Do not dismantle the steering damper XTightening torque Steering damper at slider tube bridge mount clean thread Loctite 2701 20 Nm Steering damper mount at slider tube bridge clean thread Loctite 2701 9 Nm Steering damper at leading link mount clean thread Loctite 2701 20 Nm Steering damper mount to leading link 20 Nm Join...

Page 255: ...ated handlebar grips 8 Without heated handlebar grips 8 RS Removing and installing handlebar 9 GS R RT Removing and installing handlebar 10 Removing and installing wire cable distributor block 11 Removing and installing throttle cable 12 With wire cable distribution block 13 Removing and installing cold start cable 14 With wire cable distribution block 14 Removing and installing clutch cable 15 32...

Page 256: ...32 2 ...

Page 257: ...32 3 32 Technical Data R 1100 RS Steering lock angle 2 x 32 Steering head tube dia mm in 22 0 866 Handlebar width with weights mm in 738 29 055 ...

Page 258: ...32 4 Technical Data R 1100 RT Steering lock angle 2 x 34 Steering head tube dia mm in 22 0 866 Handlebar width with weights mm in 775 30 512 ...

Page 259: ...32 5 Technical Data R 850 GS R 1100 GS Steering lock angle 2 x 42 2 x 42 Steering head tube dia mm in 22 0 866 22 0 866 Handlebar width with weights mm in 890 35 0397 890 35 0397 ...

Page 260: ...32 6 Technical Data R 850 R R 1100 R Steering lock angle 2 x 37 2 x 37 Steering head tube dia mm in 22 0 866 22 0 866 Handlebar width with weights mm in 780 30 7087 780 30 7087 ...

Page 261: ... handlebar fitting end Unfasten retaining screws for heated handlebar grip Separate connector to heated handlebar grip Unfasten cable shoes at connector Pull lead through handlebar Without heated handlebar grips Cut through rubber grip and pull it off Loosen clamp screw 4 on handlebar fitting Remove fitting from handlebar Install in the reverse order of work Align slot of handlebar fitting arrow w...

Page 262: ...eated handlebar grip Separate connector to heated handlebar grip Unfasten cable shoes at connector Pull lead through handlebar Without heated handlebar grips Cut open rubber grip 4 and pull off Unfasten clamp screw 5 from fitting housing Remove handlebar fitting Install in the reverse order of work Align slot of handlebar fitting arrow with punch mark on handlebar Secure rubber handlebar grip with...

Page 263: ...ion of arrow Remove handlebar Install in the reverse order of work eCaution Ensure that brake hoses are correctly located XTightening torquet Handlebar at rubber mount 40 Nm Rubber mount at fork bridge 40 Nm Handlebar weight to fixed handlebar 20 Nm Handlebar weight to adjustable handlebar clean thread Loctite 2701 7 Nm 1 RS320030 ...

Page 264: ...andlebar Install in the reverse order of work eCaution Make sure that brake hoses are correctly routed GS Align punch mark on handlebar with gap be tween clamp blocks XTightening torque Clamp to fork bridge GS 21 Nm Handlebar to fork bridge R RT 21 Nm Weight to handlebar 20 Nm GS R RT GS320030 ...

Page 265: ... wire cable Remove the cable cover at the throttle operating fitting Detach the wire cables at the left and right throttle stub pipes Relesse the cable straps Detach the engine breather pipe 1 from the en gine Pull the wire cable distributor block 2 out of holder 3 in the direction of the arrow Install in the reverse order of work Adjust the wire cables a See Group 00 1 3 2 RT320120 ...

Page 266: ... cable Unfasten cable adjusting screw 2 on the right throttle body Press in retaining spring 3 and disconnect ca ble Unfasten both cable adjusting screws 4 on left throttle body Press in retaining spring 5 and disconnect cable Install in the reverse order of work eCaution Install wire cable without kinking Adjust wire cable a See Group 00 1 RS320041 2 GS320110 3 4 4 5 RS320050 ...

Page 267: ...sting screws 2 at the right and left throttle stub pipes Press in retaining spring 3 and disconnect the cables Pull out the cable distribution block 6 in the di rection of the arrow Release the keeper 7 and remove the distribut ing disk 8 Disconnect cables 9 10 and 11 Install in the reverse order of work Adjust the wire cables a See Group 00 8 7 6 9 10 11 RT320130 ...

Page 268: ...stall wire cable without kinking Adjust wire cable a See Group 00 With wire cable distribution block Remove cable cover at throttle fitting disconnect the cable Remove actuating lever 1 disconnect cable Remove the cable adjusting screws at the right and left throttle stub pipes Press in the retaining spring and remove the cable Remove the wire cable distribution block 4 in the direction of the arr...

Page 269: ... Detach fuel tank and pull it to the rear Disconnect clutch cable from release lever gear box Disconnect clutch cable from handlebar lever Install in the reverse order of work eCaution Install wire cable without kinking Adjust wire cable a See Group 00 RS320081 RS320091 ...

Page 270: ...aper roller bearing in rear wheel drive 15 Removing crown wheel 16 Installing crown wheel 17 Checking adjusting backlash 18 Checking tooth contact pattern 19 Shimming housing cover 20 Installing housing cover 20 Installing splined element 20 Installing rear wheel drive 21 Removing dismantling reassembling and installing rear swinging arm 23 Removing rear swinging arm 23 Removing and installing tap...

Page 271: ...33 2 ...

Page 272: ...oil SAE 90 GL 5 Filling capacity Initial filling l Imp pints 0 25 0 44 Oil changes l Imp pints 0 23 0 405 Drive shaft Layout Two piece drive shaft with integral torsional vibra tion damper enclosed in single swinging arm BMW PARALEVER universal joints at both ends sliding joint at rear wheel drive end Swinging arm Swinging arm length mm in 355 13 976 Rear suspension Suspension strut Suspension str...

Page 273: ...ial filling l Imp pints 0 25 0 44 Oil changes l Imp pints 0 23 0 405 Drive shaft Layout Two piece drive shaft with integral torsional vibra tion damper enclosed in single swinging arm BMW PARALEVER universal joints at both ends sliding joint at rear wheel drive end Swinging arm Swinging arm length mm in 355 13 976 Rear suspension Suspension strut Suspension strut with single tube gas filled shock ...

Page 274: ...ges l Imp pints 0 23 0 405 0 23 0 405 Drive shaft Layout Two piece drive shaft with integral torsional vibra tion damper enclosed in single swinging arm BMW PARALEVER universal joints at both ends sliding joint at rear wheel drive end Swinging arm Swinging arm length mm in 355 13 976 355 13 976 Rear suspension Suspension strut Suspension strut with single tube gas filled shock absorber contin uous...

Page 275: ...Imp pints 0 23 0 405 0 23 0 405 Drive shaft Layout Two piece drive shaft with integral torsional vibra tion damper enclosed in single swinging arm BMW PARALEVER universal joints at both ends sliding joint at rear wheel drive end Swinging arm Swinging arm length mm in 355 13 976 355 13 976 Rear suspension Suspension strut Suspension strut with single tube gas filled shock absorber contin uously var...

Page 276: ...33 7 Rear wheel drive sectioned drawing RS339011 ...

Page 277: ...33 8 ...

Page 278: ...xed bearing journal 4 to max 120 C loosen RS R RT Remove brake disk heat retaining bolts to 120 C with ABS mark position before removing Remove free bearing fixed bearing journal 3 4 L Note Inner races of needle bearings Detach strut from rear wheel drive Disconnect rear wheel drive from drive shaft L Note If rear wheel drive is filled with oil do not place on side prior to installation this will ...

Page 279: ...ut 5 at input bevel pinion to 100 C and unscrew it with 36 mm socket wrench insert and reducing adapter 1 BMW No 33 1 720 eCaution Never use a hammer when loosening the hex nut this could damage the splines Remove thrust ring 6 Heat housing to 120 C and unscrew threaded ring 7 with pin wrench 2 BMW No 33 1 700 To remove the input bevel pinion 8 heat bear ing seat to 120 C 8 7 6 5 j 100 j 120 LT330...

Page 280: ...om housing Clamp input bevel pinion 6 into vise with protec tive jaws splines facing upwards Using puller BMW No 00 7 500 pull off both bearings at the same time Take off ball thrust bearing 9 inner race 10 roller bearing cage 11 and outer race 12 12 11 10 9 7 8 6 LT330030 00 7 500 LT330040 ...

Page 281: ...l out the needle roller bearing outer race with internal puller BMW No 00 8 573 and counter support BMW No 00 8 570 Installing needle roller bearing for input bevel pinion Heat the needle roller bearing seat to 100 C Press in needle roller bearing using drift or the in put bevel pinion LT330020 LT 33 006 00 8 570 00 8 573 RT330060 ...

Page 282: ...push onto input bevel pinion 6 as far as the stop Slide outer race 12 together with roller cage 11 onto inner race 10 Heat ball thrust bearing 9 to 100 C and push onto input bevel pinion 6 as far as the stop Allow input bevel pinion to cool down 12 11 10 9 6 j 100 LT330071 ...

Page 283: ... 5 with Hylomar SQ 32 M Tighten threaded ring with pin wrench BMW No 33 1 700 Install thrust ring 4 L Note Ensure that lip of shaft seal is perfectly aligned on thrust ring Tighten hex nut 3 using Loctite 273 eCaution Nut must not damage shaft sealing ring XTightening torque Threaded ring thread cleaned Hylomar SQ 32 M 118 Nm Nut for input bevel pinion thread cleaned Loctite 273 200 Nm 7 8 13 5 4 ...

Page 284: ...ar wheel drive Pull out needle roller bearing using counter support 22 1 BMW No 00 8 572 and internal puller 21 4 BMW No 00 8 573 Heat neck of housing to 120 C Press in needle roller bearing with inner race on drift BMW No 36 3 700 00 8 573 00 8 572 RT330090 ...

Page 285: ...cover to 100 C and pull it off Force shaft seal 4 out of housing cover with drift Clamp crown wheel in vise with protective jaws Insert pressure block BMW No 33 1 307 arrow Using puller BMW No 33 1 830 pull off the deep groove ball bearing 1 2 3 4 j 100 LT330111 RT330121 33 1 307 33 1 830 LT330130 ...

Page 286: ...d handle BMW No 00 5 500 Check that outer race is correctly fitted by strik ing gently L Note If new parts are installed e g taper roller bearing check tooth backlash and adjust if necessary Place the existing spacer ring 1 on the crown wheel Heat taper roller bearing 2 to 80 C and push it on Install crown wheel 3 Heat deep groove ball bearing 4 to 80 C and place it in position 00 7 500 LT330140 0...

Page 287: ...d press the crown wheel into the housing and turn to and fro to check tooth backlash L Note Check tooth backlast at three points 120 degrees apart turn the bevel pinion with the crown wheel Compensate for excessive backlash by inserting a thinner shim washer and for insufficient back lash by inserting a thicker shim washer 1 Backlash adjusting without oil 0 07 0 16 mm 0 00276 0 0063 in 33 2 604 33...

Page 288: ...ss into housing with the palms of the hands and turn to and fro If the correct spacer disc is installed the follow ing contact pattern appears when no load is ap plied L Note The contact point is central on front flank V The contact point is closer to the larger diameter on back flank R eCaution Teeth should never make contact at the smaller di ameter If this contact pattern is obtained a thinner ...

Page 289: ...ight coat of grease to the selected shim washer and install it Preload 0 05 0 1 mm 0 00197 0 03937in Installing housing cover Using drift BMW No 33 1 860 and handle BMW No 00 5 500 drive in the sealing ring Install O ring and apply a light coat of oil grease Heat housing cover to 80 C install Tighten retaining bolts in a crosswise pattern XTightening torque Housing cover 35 Nm Installing splined e...

Page 290: ...gth of the thread on free bearing pin 4 and screw it in Tighten fixed bearing of swinging arm XTightening torque Fixed bearing journal thread cleaned Loctite 2701 150 Nm eCaution When threaded connections are made with the aid of Loctite 2701 they must be tightened to their final torque without delay The Loctite hardening time is at least 3 hours L Note Use an acetone based cleaning agent e g Loct...

Page 291: ...pints During oil changes 0 23 l 0 405 Imp pints Oil grade Brand name hypoid gear oil SAE 90 API class GL 5 ABS RS R RT Install the brake disc in the previously marked position Install the rear wheel Install brake caliper eCaution Do not damage brake pads do not tilt when installing GS R RT ABS Install the sensor ABS Check that sensor gap is correct ABS rear sensor gap 0 45 0 55 mm 0 0177 0 02165 i...

Page 292: ... plates Heat free swinging arm bearing 2 to max 120 C loosen Heat fixed swinging arm bearing 3 to max 120 C unscrew Unfasten free swinging arm bearing Removing and installing taper roller bearing Using counter support BMW No 00 8 572 and internal puller 21 2 BMW No 00 8 571 pull out taper roller bearing Pull out outer race with internal puller 21 5 BMW No 00 8 563 To install the bearing heat the s...

Page 293: ...om pressed aperture in retaining ring must be horizontal Removing drive shaft Press off drive shaft eCaution Do not scratch painted components if necessary use a rubber mat Checking universal joint for wear Determine end float and face runout Installing drive shaft Coat the splines on the output shaft with Staburags NBU 30 PTM Fit drive shaft to output shaft Engage the snap ring with gentle blows ...

Page 294: ...be applied without delay The Loctite has a hardening time of at least 3 hours L Note Use acetone based cleaning agents e g Loctite Rapid Cleanser 706 Loctite Order No 70636 AC Tighten free bearing journal XTightening torque Free bearing journal Thread cleaned Loctite 2701 applied to entire length of thread on free bearing journal 7 Nm Locknut 105 Nm RT Attach gear shift linkage to left footrest pl...

Page 295: ...e rear wheel GS Unscrew hydraulic spring adjuster using 6 mm Allen key BMW No 31 5 600 Remove install suspension strut XTightening torque Suspension strut on swinging arm rear frame RS 8 8 screw 43 Nm RS 10 9 screw 50 Nm GS R RT 10 9 screw 50 Nm Hydraulic spring adjuster at footrest plate 22 Nm RS RS330050 GS RT GS330440 ...

Page 296: ...er 12 Assembling rear brake caliper 12 Removing and installing front brake disc 13 RS Removing and installing rear brake disc attached to rear wheel drive 14 GS R Removing and installing rear brake disc attached to rear wheel hub 14 RT R Removing and installing rear brake disc attached to rear wheel drive 15 RS Removing and installing front ABS sensor 16 GS R Removing and installing front ABS sens...

Page 297: ... Removing and installing rear brake master cylinder 25 Checking and adjusting relief clear ance of piston rod 25 Removing and installing brake pedal 26 Removing and installing ABS unit 27 Removing the ABS unit 28 Installing the ABS unit 28 Removing and installing ABS relay and relay base 29 Removing ABS relay 29 Installing the ABS relay 29 Removing ABS relay base 30 Installing the ABS relay base 3...

Page 298: ...8 1 3386 Piston diameter in handlebar lever cylinder mm in 20 0 787 Sensor gap front mm in 0 45 0 55 0 0177 0 02165 Brake pad Sintered metal Rear wheel Brake disc dia mm in 285 11 22 Brake disc thickness mm in 5 0 0 1969 Minimum thickness mm in 4 6 0 1811 Permissible lateral runout mm in 0 20 0 00787 Brake pad surface area cm2 sq in 41 5 6 4325 Piston dia in brake caliper mm in 38 1 496 Piston dia...

Page 299: ... Piston diameter in handlebar lever cylinder mm in 20 0 787 Sensor gap front mm in 0 45 0 55 0 0177 0 02165 Brake pad Semi metallic Rear wheel Brake disc dia mm in 276 10 866 Brake disc thickness mm in 5 0 0 1969 Minimum thickness mm in 4 5 0 177 Permissible lateral runout mm in 0 15 0 0059 Brake pad surface area cm2 sq in 34 5 27 Piston dia in brake caliper mm in 26 1 0236 with insulating piston ...

Page 300: ...bar lever cylinder mm in 20 0 787 20 0 787 Sensor gap front mm in 0 45 0 55 0 0177 0 02165 0 45 0 55 0 0177 0 02165 Brake pad Semi metallic Semi metallic Rear wheel Brake disc dia mm in 276 10 866 276 10 866 Brake disc thickness mm in 5 0 0 1969 5 0 0 1969 Minimum thickness mm in 4 5 0 177 4 5 0 177 Permissible lateral runout mm in 0 15 0 0059 0 15 0 0059 Brake pad surface area cm2 sq in 34 5 27 3...

Page 301: ... 0 45 0 55 0 0177 0 02165 0 45 0 55 0 0177 0 02165 Brake pad Semi metallic Semi metallic Rear wheel Brake disc dia mm in 276 10 866 276 10 866 Brake disc thickness mm in 5 0 0 1969 5 0 0 1969 Minimum thickness mm in 4 6 0 1811 4 5 0 177 Permissible lateral runout mm in 0 15 0 0059 Spoked wheel 0 15 0 0059 Spoked wheel mm in 0 15 0 0059 Cast wheel 0 15 0 0059 Cast wheel Brake pad surface area cm2 s...

Page 302: ...ds pistons arrows Carefully remove the brake calipe eCaution RS R RT Do not scratch the wheel rim if neces sary mask off the brake caliper with tape Do not damage brake pads Install in the reverse order of work Force back the brake pads pistons Fill bleed the brake system eCaution Use new sealing rings 2 Do not damage brake pads XTightening torque Brake caliper to slider tube 40 Nm Brake hose to b...

Page 303: ...ut brake pistons 2 using a compressed air gun at the brake line connection e Caution Do not allow your fingers to become trapped be tween the pistons risk of injury Remove the two sealing rings 3 4 from the left right brake cylinder bores Examine the brake caliper pistons for damage Assembling front brake caliper Coat new sealing rings 3 4 with brake fluid and install Coat brake caliper pistons 2 ...

Page 304: ...l in the reverse order of work Force back the brake pads pistons Fill bleed the brake system R RT To bleed detach the brake caliper and position it with the bleed nipple at the highest point eCaution Renew sealing rings for brake line Do not damage brake pads ABS Check sensor gap and adjust if necessary with spacing plate Sensor gap 0 45 0 55 mm 0 0177 0 02165in XTightening torque Brake caliper to...

Page 305: ...protection sleeve 6 at left right Seal the bleed screw XTightening torque Bleed screw at brake caliper 7 Nm Hold a cloth over the brake caliper Carefully press our brake piston 7 with a com pressed air gun at the connecting bore working at low air pressure eCaution Do not allow your fingers to be trapped by the pis ton risk of injury Remove sealing ring 8 from the left right wheel brake cylinders ...

Page 306: ...ders Coat both brake caliper pistons 7 with brake flu id and install them eCaution Do not tilt the brake pistons when assembling Insert the dust protection sleeve 6 at left and right Before installing the new brake pads press the pistons back into the brake calipers with the re setting device BMW No 34 1 500 34 1 500 RS340150 ...

Page 307: ...risk of injury Remove sealing rings 4 from left right cylinder Inspect the brake caliper piston for hairline cracks score marks other damage Assembling rear brake caliper Coat the new sealing rings with brake fluid and insert them into the left right brake caliper cylin ders Coat both brake caliper pistons with brake fluid and install them eCaution Do not tilt the brake pistons when installing Coa...

Page 308: ...ction arrow of brake discs must be correct XTightening torque Brake disc to front wheel RS RT 21 Nm GS clean thread Loctite 243 24 Nm R Cast alloy front wheel 21 Nm R Spoked front wheel clean thread Loctite 243 24 Nm eCaution Check adjust sensor gap if exchanged apply a new sensor gap measuring mark Sensor gap 0 45 0 55 mm 0 0177 0 02165 in RS340080 RS ...

Page 309: ...d therefore the sensor wheel are renewed the disc s vertical runout must be determined marked Sensor gap 0 45 0 55 mm 0 0177 0 02165 in XTightening torque Brake disc to rear wheel drive clean thread Loctite 273 21 Nm GS R Removing and installing rear brake disc attached to rear wheel hub Remove the brake caliper Remove rear wheel Remove brake disc Install in the reverse order of work Degrease the ...

Page 310: ...runout of sensor wheel is not changed Install in the reverse order of work Degrease the brake disc before installing eCaution ABS Check sensor gap and adjust with spacing plates if necessary ABS If the brake disc and therefore the sensor wheel are renewed the disc s lateral runout must be determined marked Sensor gap 0 45 0 55 mm 0 0177 0 02165 in XTightening torque Brake disc to rear wheel drive ...

Page 311: ...guard Separate plug connector 1 in sensor line Remove sensor 2 with Torx T 25 Install in the reverse order of work eCaution Run the sensor line correctly Check sensor gap and adjust if necessary with spacer plate 3 Sensor gap 0 45 0 55 mm 0 0177 0 02165 in XTightening torque Sensor handtight 4 Nm 1 3 2 RS340090 ...

Page 312: ... tank Separate plug connector 1 in sensor line Remove sensor 2 with Torx T 25 Install in the reverse order of work eCaution Run the sensor line correctly Check sensor gap and adjust if necessary with spacer plate 3 Sensor gap 0 45 0 55 mm 0 0177 0 02165 in XTightening torque Sensor handtight 4 Nm 3 2 1 GS340090 ...

Page 313: ...rd Separate plug connector 1 in sensor line Remove sensor 2 with Torx T 25 Install in the reverse order of work eCaution Run the sensor line correctly Check sensor gap and adjust if necessary with spacer plate 3 Sensor gap 0 45 0 55 mm 0 0177 0 02165 in XTightening torque Sensor handtight 4 Nm RT340090 1 3 2 ...

Page 314: ...e sensor is farthest away from the sensor wheel arrow eCaution If parts are replaced brake disc etc and a used or previously marked sensor wheel is installed the sensor ring must be measured and marked again Remove the old marking Checking and adjusting sensor gap Check adjust at the marked point If necessary remove install sensor with Torx T 25 and adjust sensor gap with spacing plates Sensor gap...

Page 315: ...rx T 25 detach sensor 1 Separate the plug connector 2 in the sensor line Install in the reverse order of work eCaution Check sensor gap and adjust if necessary with spacer plates 3 Run the sensor line correctly Sensor gap 0 45 0 55 mm 0 0177 0 02165 in XTightening torque Sensor handtight 4 Nm 1 3 2 RS340170 ...

Page 316: ...Detach sensor 1 with Torx T 25 Separate plug connector 2 in the sensor line Install in the reverse order of work Coat O rings with oil before installing eCaution Run the sensor line correctly Check sensor gap and adjust if necessary with spacer plates 3 Sensor gap 0 45 0 55 mm 0 0177 0 02165 in XTightening torque Sensor handtight 4 Nm 1 3 2 GS340170 ...

Page 317: ...nt where the sensor wheel is farthest away from the sensor arrow eCaution If parts are replaced brake disc etc and a used or previously marked sensor wheel is installed the sensor ring must be measured and marked again Remove the old marking Checking and adjusting sensor gap Check adjust at the marked point In necessary remove install sensor with Torx T 25 and adjust sensor gap with spacing plates...

Page 318: ...nsor wheel is farthest away from the sensor arrow eCaution If parts are replaced rear wheel etc and a used or previously marked sensor wheel is installed the sensor ring must be measured and marked again Remove the old marking Checking and adjusting sensor gap Check adjust at the marked point If necessary remove install sensor with Torx T 25 and adjust sensor gap with spacing plates eCaution After...

Page 319: ... of sleeves face the pressure chamber Fill bleed the brake system Adjusting specification for handbrake lever Clean grub screw 7 coat it with Loctite 270 and screw it in until there is no play at the handlebar lever then tighten it further by pre cisely one half turn eCaution Never tighten the grub screw by more than this ad ditional half turn or else the brake could fail or be locked on Seal grub...

Page 320: ...inder Install in the reverse order of work Tighten non reusable hose clip 2 with pliers BMW No 13 1 500 eCaution Bleed the brake system carefully Check adjust piston rod snifting action play XTightening torque Master cylinder to footrest plate 9 Nm Checking and adjusting relief clear ance of piston rod Insert a feeler gauge of the correct thickness be tween the adjusting screw brake lever and the ...

Page 321: ...stall in the reverse order of work Lubricate pivot bushing with Shell Retinax A eCaution Check adjust piston rod relief clearance See removal and installation of brake master cylin der The brake light must come on as soon as the rear brake begins to take effect XTightening torque Brake pedal to footrest plate free from grease 37 Nm 1 GS RS340220 ...

Page 322: ...34 27 Removing and installing ABS unit eCaution Work on the ABS unit is only to be performed by an authorized BMW workshop 1 3 2 4 6 5 RS340010 ...

Page 323: ...tion Make sure the cable is not at an angle or its insula tion may be damaged Reconnect the 2 pin plug in the correct position pushing the two halves fully together and press the two wires into the center smaller cable en tries Push the two plugs for the connecting cable wiring harness onto the threaded pins with the crimp at the front Press the two cables into the remaining free cable entries Tig...

Page 324: ...relay base Push the relay base into the relay housing at the same time pressing both engine cables into the left cable entries on the relay housing red at bot tom black at top Attach black engine cable to left threaded pin M5 with crimp at back eCaution Make sure the cable is not at an angle or its insula tion may be damaged Attach 2 pin plug in correct position pushing it on fully and press the t...

Page 325: ...the relay base Working from the relay side release the plug with special tool Art No 50000 017 507 from the Grote und Hartmann company eCaution The contact has a double detent When pulling the plug out of the relay base avoid applying too much tension to the cable If the cable breaks the complete ABS unit will have to be exchanged Installing the ABS relay base Bend up the contact interlock on the ...

Page 326: ...ush the relay base into the relay housing at the same time pressing both engine cables into the left cable entries on the relay housing red at bot tom black at top Attach black engine cable to left threaded pin M5 with crimp at back eCaution Make sure the cable is not at an angle or its insula tion may be damaged Push the 2 pin plug fully on in the correct posi tion and press the two wires into th...

Page 327: ...34 32 Removing and installing brake line with ABS Removing and installing front ABS brake line RS RS340040 ...

Page 328: ...34 33 Removing and installing rear ABS brake line RS RS340030 ...

Page 329: ...ndlebar is turned RS adjustable handlebar In its center position the brake hose fitting must have adequate clearance at the center section of the handlebar app 5 10 mm 0 11969 0 3937in If necessary unfasten the wiring harness Fill bleed the brake system XTightening torque Brake line to fitting 15 Nm Brake line to front rear brake caliper 15 Nm Brake line at fluid distributor 15 Nm Flow distributor...

Page 330: ...ar wheel cast alloy 10 Removing rear wheel 10 Installing rear wheel 10 GS R Removing and installing rear wheel spoked 11 Removing rear wheel 11 Installing rear wheel 11 Static balancing of front wheel rear wheel 12 Checking front rear wheel rim for runout 13 GS R spoked wheel Removing and installing spokes 14 GS R spoked wheel Centering wheel rim 14 Centering horizontal runout 14 36 Wheels and tyr...

Page 331: ...36 2 ...

Page 332: ... in 0 5 0 0197 rear mm in 0 3 0 0118 Tyre size Cast wheel front 120 70 ZR 17 Tubeless rear 160 60 ZR 18 Tubeless Tyre pressure cold Solo front bar psi 2 2 31 91 rear bar psi 2 5 36 26 With pillion passenger front bar psi 2 5 36 26 rear bar psi 2 7 39 16 With pillion passenger and luggage front bar psi 2 5 36 25 rear bar psi 2 9 42 06 ...

Page 333: ...in 0 5 0 0197 rear mm in 0 3 0 0118 Tyre size Cast wheel front 120 70 ZR 17 Tubeless rear 160 60 ZR 18 Tubeless Tyre pressure cold Solo front bar psi 2 2 31 91 rear bar psi 2 5 36 26 With pillion passenger front bar psi 2 5 36 26 rear bar psi 2 7 39 16 With pillion passenger and luggage front bar psi 2 5 36 25 rear bar psi 2 9 42 06 ...

Page 334: ... 0 0512 Tyre size Spoked wheel Spoked wheel front 110 80 R 19 59 H Tubeless 110 80 R 19 59 H Tubeless rear 150 70 R 17 69 H Tubeless 150 70 R 17 69 H Tubeless Tyre pressure cold Solo front bar psi 2 2 31 91 2 2 31 91 rear bar psi 2 5 36 26 2 5 36 26 With pillion passenger front bar psi 2 5 36 26 2 5 36 26 rear bar psi 2 7 39 16 2 7 39 16 With pillion passenger and luggage front bar psi 2 5 36 25 2...

Page 335: ...t mm in 1 3 0 0512 1 3 0 0512 rear mm in 1 3 0 0512 1 3 0 0512 Tyre size Cast wheel Cast wheel front 120 70 ZR 17 Tubeless 120 70 ZR 17 Tubeless rear 160 60 ZR 18 Tubeless 160 60 ZR 18 Tubeless Spoked wheel Spoked wheel front 110 80 ZR 18 Tubeless 110 80 ZR 18 Tubeless rear 150 70 ZR 17 Tubeless 150 70 ZR 17 Tubeless Tyre pressure cold Solo front bar psi 2 2 31 91 2 2 31 91 rear bar psi 2 5 36 26 ...

Page 336: ...ont wheel Installing front wheel Install front wheel Install spacer bushing and speedometer drive eCaution Anti twist device arrow on speedometer drive is lo cated in front of stop on slider tube Apply a light coating of Molykote paste to the quick release axle install it Tighten retaining screw 1 Press forks down firmly several times Tighten clamping screws 2 Install brake calipers RS RT Install ...

Page 337: ...heel hub right side of wheel and claws of inter nal puller Heat bearing seat to 80 C Pull out wheel bearing with counter support 22 1 BMW No 00 8 572 and internal puller 21 3 BMW No 00 8 574 Press out spacing bushing 1 and wheel bearing 2 with drift BMW No 36 5 530 Press reducing bushing out of bearing with drift BMW No 36 5 530 into new bearing Degrease bearing seats RS360021 00 8 572 00 8 574 31...

Page 338: ... 2 in contact with arbor Install spacer tube 1 Bearing seat temperature 80 C Insert narrow bearing 3 with drift BMW No 36 5 512 and handle BMW No 00 5 500 Install retaining ring and driver Drive in shaft sealing ring with drift BMW No 36 5 500 and handle BMW No 00 5 500 j 80 RS360025 00 5 500 36 5 511 RS360026 00 5 500 36 5 511 1 2 3 00 5 512 RS360028 00 5 500 36 5 500 RS360027 ...

Page 339: ...ree from grease RS ABS Press the muffler outwards Fit rear wheel to rear wheel drive with spacer disc 1 and insert wheel studs hand tight eCaution Only use wheel studs with length code 60 Do not oil or grease wheel studs Tighten wheel studs Install hub cap 2 L Note Insert lug on cover in recess in wheel Install number plate holder RS ABS Bolt on the muffler mount XTightening torque Screw in wheel ...

Page 340: ...n rear wheel drive and hub must be clean and free of grease Fit rear wheel to rear wheel drive and screw in wheel studs hand tight eCaution Only use wheel studs with length code 60 Do not oil or grease wheel studs Tighten wheel studs XTightening torque Screw in the wheel studs handtight and tighten them in a crosswise pattern Initial tightening 50 Nm Final tightening 105 Nm Install brake caliper A...

Page 341: ...ering collar side with the wheel studs and spacing washer then install the balancing shaft Align the balancing fixture BMW No 36 3 600 with knurled screws bubble gauge 5 6 Allow wheel to settle Clean point of adhesion Attach adhesive weights 7 opposite heaviest point of wheel arrow evenly distributed on both sides left right of rim eCaution Maximum balancing weight 60 g 2 1 oz Repeat balancing pro...

Page 342: ...ntering collar side with the wheel studs and a spacing washer then install the balancing shaft Clamp locating discs BMW No 36 3 615 on the balancing shaft at left and right so that the shaft cannot wander Align the balancing fixture BMW No 36 3 600 with knurled screws bubble gauge 5 6 Check radial axial runout eCaution Only apply dial gauge to machined inner face of wheel rim Max vertical runout l...

Page 343: ...ke nipples must be tightened on the side directly opposite the lar gest deviation Remove grub screw from relevant spoke nipple before tightening Working forwards and backwards from the max imum and minimum value points take up slack at every 3rd spoke nipple eCaution Never attempt to compensate for the entire horizon tal runout at only one or two spokes At the point where the maximum plus and minu...

Page 344: ...g number plate mount 17 RT Removing and installing lower rear section 18 RT GS R Removing and installing center stand 19 Removing and installing side stand 20 RT Removing and installing left footrest plate 21 RT Removing and installing right footrest plate 22 RT Removing and installing frame 23 RS Removing and installing front mudguard 24 RS Removing and installing side sections of fairing 25 RS R...

Page 345: ... plate 40 RS R Removing and installing front footrest plate 41 GS R Removing and installing front mudguard 42 GS Removing and installing windshield 43 GS Removing and installing front fairing 44 GS Removing and installing fairing holder 45 GS Removing and installing luggage rack 46 GS R Removing and installing number plate bracket 47 GS R Removing and installing rear mudguard 48 GS R Removing and ...

Page 346: ...0 31 496 with adjustable seat mm in 780 800 820 30 71 31 496 32 28 Wheelbase in normal load position mm in 1473 57 99 Ground clearance in normal load position mm in 153 6 024 Caster angle in normal load position mm in 111 4 37 Steering head angle in normal load position 64 5 Max heel angle with 85 kg 187 425 lb rider 49 Max wheel track offset mm in 9 0 354 Unladen weight ready for road full tank k...

Page 347: ...n 800 31 496 with adjustable seat mm in 780 800 820 30 71 31 496 32 28 Wheelbase in normal load position mm in 1485 58 4645 Ground clearance in normal load position mm in 153 6 024 Caster angle in normal load position mm in 122 4 803 Steering head angle in normal load position 62 9 Max heel angle with 85 kg rider 46 Max wheel track offset mm in 9 0 354 Unladen weight ready for road full tank kg lb...

Page 348: ...ight mm in 840 860 33 07 33 858 840 860 33 07 33 858 Wheelbase in normal load position mm in 1509 59 409 1509 59 409 Ground clearance in normal load position mm in 200 7 874 200 7 874 Caster angle in normal load position mm in 115 4 5275 115 4 5275 Steering head angle in normal load position 62 9 62 9 Max heel angle with 85 kg rider 47 47 Max wheel track offset mm in 9 0 354 9 0 354 Unladen weight...

Page 349: ...t unladen weight mm in 760 780 800 760 780 800 Wheelbase in normal load position mm in 1487 58 543 1487 58 543 Ground clearance in normal load position mm in 138 5 433 138 5 433 Caster angle in normal load position mm in 127 5 127 5 Steering head angle in normal load position 61 9 61 9 Max heel angle with 85 kg rider 45 45 Max wheel track offset mm in 9 0 354 9 0 354 Unladen weight ready for road ...

Page 350: ...46 7 General view frame RS469010 ...

Page 351: ...x 6x 2x 3x 2x 2x 4x 2x 2x 2x 2x 2x 2x 2x 2x 2x 4x 4x 3x um 90 gedreht 0 1 2 3 4 5 6 7 8 9 10 10 0 20 20 40 40 60 60 80 80 100 100 km h km h 120 120140 140 160 160 180 180 200 200 220 220 240 240 000 0000 0000 25 0000 25 4x 2x 10x 3x 4x 4x 3x 2x 1x 4x 2x ...

Page 352: ...46 9 RT Removing and installing front mudguard RT460260 ...

Page 353: ... hand strike the mirror housing lightly towards the mir ror surface arrow Take off the mirror Remove side sections of fairing 2 and spoiler 3 Install in the reverse order of work Offer the mirror at its three mounting points Strike the mirror housing lightly first at the front then at the rear to engage it 6x 2x 4x 4x 3x 4x 1 2 3 RT460270 RT460280 ...

Page 354: ... trim panels Remove windshield 1 Remove inner cover for trim Pull off plug at headlight Detach the aerial Remove upper section of fairing Remove bracket 2 for windshield Separate the plug connection and remove the electric drive 3 Install in the reverse order of work 4x 4x 3x 1x 1 2 3 RT460290 ...

Page 355: ...Removing and installing inner fairing panel 0 1 2 3 4 5 6 7 8 9 10 10 0 20 20 40 40 60 60 80 80 100 100 km h km h 120 120 140 140 160 160 180 180 200 200 220 220 240 240 000 0000 000025 000025 4x 2x 10x RT460300 ...

Page 356: ...nd earth lead Remove dualseat Remove side mirrors Remove side trim panels Remove windshield Remove inner cover for trim Pull off plug for headlight Detach the aerial Remove upper section of fairing Install in the reverse order of work L Note Before installing upper section of fairing push metal bushings 1 on to threaded pins 2 2x 2 1 RT460310 ...

Page 357: ...move windshield Remove upper section of fairing Remove windshield holder Detach instrument cluster Remove storage compartment and air intake stub pipe Detach plug strips wiring harness and wires from fairing holder Detach oil cooler mount Remove trim support bracket L Note Do not scratch the mudgard when setting down the oil cooler Install in the reverse order of work XTightening torque Fairing su...

Page 358: ...46 15 RT Removing and installing lug gage rack case holder Remove dualseat Remove luggage rack case holder Install in the reverse order of work 2x 4x RT460320 ...

Page 359: ...Remove dualseat Remove small side sections of fairing Remove rear light Remove luggage rack and case holder Remove rear fairings 1 and 2 Install in the reverse order of work L Note When installing note right and left rubber buffers 3 3 1 2 RT460331 ...

Page 360: ...46 17 RT Removing and installing number plate mount Remove dualseat Remove number plate bracket Install in the reverse order of work 3x 2x 2x RT460340 ...

Page 361: ...Disconnect ground earth lead from battery Insulate ground earth lead Remove dualseat Remove small side sections of fairing Remove rear light Remove luggage rack and case holder Remove rear trim panel Remove lower rear section Install in the reverse order of work 2x 2x 2x 2x RT460350 ...

Page 362: ...ter stand Disconnect plug from side stand switch Remove left right pivot mounts 2 Install in the reverse order of work Lubricant e g Staburags NBU 30 PTM XTightening torque Center stand to carrier plate clean thread Loctite 2701 21 Nm Carrier plate to engine block M 12 clean thread Loctite 2701 72 Nm Carrier plate at engine block M8 countersunk screw clean thread Loctite 2701 21 Nm Side stand to p...

Page 363: ...side stand Disconnect plug 1 from side stand switch and remove switch Install in the reverse order of work eCaution Note correct cable run arrow Lubricant e g Staburags NBU 30 PTM XTightening torque Side stand to pivot mount clean thread Loctite 2701 42 Nm 1 RS610050 GS460220 ...

Page 364: ...ft side section of fairing Detach gear shift linkage 1 from footrest plate Detach power socket retaining bracket 2 Remove the footrest plate Install in the reverse order of work XTightening torque Foot pedal to footrest plate 18 Nm Footrest plate to rear frame M 6 screw 6 Nm M 8 screw 21 Nm M 10 screw 42 Nm 1 2 RT460360 ...

Page 365: ...ring Release pin on brake linkage Remove retaining screws for brake master cylin der 1 from footrest plate Detach brake pedal 2 from footrest plate Remove the footrest plate Detach the contact switch 3 Install in the reverse order of work XTightening torque Footrest plate to rear frame M 6 screw 6 Nm M 8 screw 21 Nm M 10 screw 42 Nm 1 2 3 RT460370 ...

Page 366: ...crew pin 1 from engine and remove Open cable strap 3 for ABS sensor line at fairing holder Detach fairing holder from frame e Caution Fairing section will drop unless held securely If necessary place foam rubber or similar material below fairing panel Detach struts 2 from frame and loosen at en gine Remove frame Install in the reverse order of work Pull the leading link up and secure with a strap ...

Page 367: ...46 24 RS Removing and installing front mudguard L Note Retaining screw 1 3 mm 0 118 in Allen screw 1 RS460020 ...

Page 368: ...46 25 RS Removing and installing side sections of fairing RS460060 ...

Page 369: ...46 26 RS Removing and installing side sections of full fairing RS460070 ...

Page 370: ...hield Remove windshield Remove front side sections of fairing Remove inner fairing cover Detach instrument cluster Detach top section of fairing Remove headlight Remove bracket 1 for windshield Install in the reverse order of work 1 RS460080 ...

Page 371: ...ield Remove side sections of fairing Remove inner fairing panel Turn adjusting shaft 1 counterclockwise to unfasten Detach instrument cluster Detach top section of fairing Remove headlight Remove bracket 2 for windshield Install in the reverse order of work 1 2 RS460090 ...

Page 372: ...46 29 RS Removing and installing inner fairing panel RS460100 ...

Page 373: ...th lead Remove windshield Remove side sections of fairing Remove inner fairing panel Unscrew and remove windshield adjusting shaft Detach instrument cluster Detach plug connections for flashing turn indicators Detach top section of fairing Remove headlight Remove bracket for windshield Remove fairing Install in the reverse order of work RS460110 ...

Page 374: ...ring panel Turn adjusting shaft counterclockwise to release windshield adjuster Detach instrument cluster Separate plug connectors for headlights and in dicators Remove top section of fairing with headlight Detach connector strip and wiring harness from fairing holder Detach oil cooler mount Install in the reverse order of work XTightening torque Fairing support bracket to frame 20 Nm RS460120 ...

Page 375: ...he leading link Detach struts 2 from frame and loosen at engine RS Using socket wrench insert with 6 mm 0 2362 in Allen key BMW No 31 5 600 detach ball joint at fork bridge R Detach handlebar from fork bridge R Pull headlight holder forwards Unfasten screw connection between fork bridge and frame L Note Screw pin is a press fit in ball thrust bearing remove complete unit R Detach oil cooler holder...

Page 376: ...46 33 RS Removing and installing grab handle case holder XTightening torque Grab handle to rear frame 9 Nm RS460140 ...

Page 377: ...46 34 RS Removing and installing rear fairing Remove dualseat Remove rear light Remove rear fairing panel Install in the reverse order of work RS460040 ...

Page 378: ...46 35 RS Removing and installing number plate bracket Remove dualseat Remove number plate bracket Install in the reverse order of work RS460150 ...

Page 379: ...attery Insulate ground earth lead Remove dualseat Remove number plate bracket Remove rear light Remove rear fairing Remove turn indicator lenses Disconnect detach turn indicators Detach wiring harness from lower rear section Remove dualseat lock Remove lower rear section Install in the reverse order of work RS460050 ...

Page 380: ...nsor plug and detach the cable Disconnect the brake light switch plug and de tach the cable Disconnect the side stand switch plug and de tach the cable Disconnect the neutral switch plug and detach the cable Detach diagnosis plug and cable Pull brake cable out of holder rear section of frame Pull brake fluid container out of holder Detach muffler silencer from rear section of frame Detach upper su...

Page 381: ...46 38 RS Removing and installing center stand Remove lower section of fairing 2 1 2 3 1 2 v 2701 v 2701 v 2701 v 2701 v 2701 RS460030 ...

Page 382: ...switch Remove left right bearing mount 3 Install in the reverse order of work Lubricant e g Staburags NBU 30 PTM XTightening torque Center stand to carrier plate clean thread Loctite 2701 21 Nm Carrier plate to engine block M 12 clean thread Loctite 2701 72 Nm Carrier plate at engine block M 8 countersunk screw clean thread Loctite 2701 21 Nm Side stand at bearing mount clean thread Loctite 2701 4...

Page 383: ...46 40 RS Removing and installing rear footrest plate XTightening torque Footrest to footrest plate 42 Nm Muffler silencer to footrest plate 35 Nm Footrest plate to rear frame 21 Nm RS460180 ...

Page 384: ...46 41 RS R Removing and installing front footrest plate XTightening torque Footrest plate to gearbox 22 Nm Master cylinder to footrest plate 7 Nm Brake pedal to footrest plate 37 Nm RS460190 ...

Page 385: ...46 42 GS R Removing and installing front mudguard Remove front wheel GS460021 ...

Page 386: ...46 43 GS Removing and installing windshield GS460091 ...

Page 387: ... top mudguard Remove windshield Remove headlight insert Detach instrument cluster L Note Center retaining screw 1 is inside headlight housing Remove headlight holder Remove indicator glasses pull off cable connec tor and draw cable through indicator holder Remove indicators Pull front trim section top cover upwards to re move Install in the reverse order of work GS460230 GS620020 1 ...

Page 388: ...rument cluster L Note Center retaining screw 1 is inside headlight housing Remove headlight holder Remove indicator glasses pull off cable connec tor and draw cable through indicator holder Remove indicators Pull front section of fairing top cover upwards to remove Detach wiring harness from trim holder Detach oil cooler mount Remove trim support bracket Install in the reverse order of work XTight...

Page 389: ...46 46 GS Removing and installing luggage rack GS460240 ...

Page 390: ...oving and installing number plate bracket Take off rear section of dualseat GS Remove tool box GS Remove rear light Remove turn indicators Remove number plate bracket Install in the reverse order of work GS GS460151 ...

Page 391: ...earth lead from battery Insulate ground earth lead Remove dualseat GS Remove tool box R Remove rear fairing Disconnect plugs and leads from rear light and indicators Remove number plate bracket Detach mudguard Remove wiring harness from rear section Install in the reverse order of work GS GS460251 ...

Page 392: ...46 49 GS R Removing and installing rear footrest plate XTightening torque Footrest plate to rear frame 21 Nm GS460181 ...

Page 393: ...46 50 GS Removing and installing front footrest plate XTightening torque Hydraulic spring adjuster to footrest plate 22 Nm GS460191 ...

Page 394: ...46 51 R Removing and installing rear fairing RS460041 ...

Page 395: ... in on the other side Adjust support 1 so that the measuring plane is as close as possible to the wheel centerline The gauge must slide freely up to the motorcycle Adjust measuring stops arrows until they con tact the wheel rim not the tyre Attach hook 2 to wheel spoke to secure the gauge firmly to the wheel Align front wheel parallel with the gauge Measure distance between outer edge of gauge and...

Page 396: ...urement Minus sign track offset to left Plus sign track offset to right EXAMPLE Formula Fixed value A half rim width A 50 0 mm 1 9685 in 44 5 mm 1 752 in 94 5 mm 3 72 in Measured value B half rim width B 52 0 mm 2 047in 41 0 mm 1 614 in 93 0 mm 3 66 in Fixed value A measured value B S 94 5 mm 3 72 in 93 0 3 66 in S Wheel track offset S 1 5 mm 0 059 in B B A A Fh Fh S RS460210 A Fh 2 B Fv 2 S Fh 2 ...

Page 397: ...ock barrel for fuel tank filler cap 4 Drilling out lock barrel 4 RS RT Removing and installing dualseat lock 5 Removing and installing lock barrel 5 GS Removing and installing dualseat lock 5 Removing and installing lock barrel 5 R Removing and installing dualseat lock 6 Removing and installing lock barrel 6 GS Removing and installing helmet lock 6 RT Removing and installing storage compartment lo...

Page 398: ...51 2 ...

Page 399: ...ated screws thread cleaned Loctite 270 15 Nm Removing and installing ignition light switch Remove socket head cap screw 2 Removing and installing lock barrel Key in ON position press in keeper 1 with a stiff wire or similar Pull out lock barrel with key Lubricate the new lock barrel with Shell Retinax A Insert the lock barrel with the key in the ON posi tion Press lock barrel down until keeper eng...

Page 400: ...rel and press down on re tainer 2 Pull out lock barrel with key Grease new lock barrel with Shell Retinax A Install lock barrel with key at a right angle to direction of travel Install in the reverse order of work Drilling out lock barrel Drill out entire length of lock barrel with a 4 5 mm 0 157 0 1969 in dia twist drill bit Repeat with a larger diameter drill bit until the lock barrel can be rem...

Page 401: ... engages GS Removing and installing dualseat lock Removing and installing lock barrel Remove luggage rack Remove dualseat lock Dismantle key side of dualseat lock 2 screws and open up carefully Press the locating tongue arrow of the lock bar rel in the housing and pull the lock barrel out with the key Lubricate the new lock barrel with Shell Retinax A Insert lock barrel until retainer engages Inst...

Page 402: ...hook Press retaining lug on lock barrel down into housing and remove lock barrel with key Lubricate the new lock barrel with Shell Retinax A Insert lock barrel until retainer engages Install in the reverse order of work RT Removing and installing stor age compartment lock Press in safety peg arrow with a piece of wire or similar Take off the locking section 1 Pull out lock barrel with key Lubricat...

Page 403: ...52 1 Contents Page 52 RT Dismantling and assembling dualseat 3 RS Dismantling and assembling dualseat 4 GS R Dismantling and assembling dualseat 5 52 Seat ...

Page 404: ...52 2 ...

Page 405: ...52 3 52 RT Dismantling and assembling dualseat RS520013 ...

Page 406: ...52 4 RS Dismantling and assembling dualseat RS520011 ...

Page 407: ...52 5 GS R Dismantling and assembling dualseat GS R RS520020 RS520013 ...

Page 408: ...al equipment box 10 Installing wiring harness in central electrical equipment box output 11 RT Wiring harness View from left 12 RT Wiring harness View from right 16 RT Wiring harness at fairing holder 19 RT Wiring harness at instrument cluster 20 RS Wiring harness View from left 21 RS Wiring harness View from right 25 RS Wiring harness at left switch unit 28 RS Wiring harness at right switch unit ...

Page 409: ...61 2 ...

Page 410: ...61 3 61 Technical Data R 1100 RS Battery Ah 19 ...

Page 411: ...61 4 Technical Data R 1100 RT Battery Ah 19 ...

Page 412: ...61 5 Technical Data R 850 GS R 1100 GS Battery Ah 19 19 ...

Page 413: ...61 6 Technical Data R 850 R R 1100 R Battery Ah 19 19 ...

Page 414: ...ower rear section Take out retaining screws 1 for upper section of central electrical equipment box Take out retaining screws 2 for lower section of central electrical equipment box Remove cable tray If necessary detach complete wiring harness and remove it with the fuse box or remove the relays and relay bases Install in the reverse order of work After assembly shorten the rubber tag on the splas...

Page 415: ...ear lights 15 Amp 2 Parking light 15 Amp 3 Flashing turn indicators clock 15 Amp 4 Power socket 15 Amp 5 Motronic 15 Amp 6 Fuel pump 15 Amp 7 Heated handlebar grips 4 Amp 8 Spare fuse 4 Amp 9 Spare fuse 15 Amp 10 Spare fuse 15 Amp Connections to fuses RT No 1 on left looking forwards 1 Instrument cluster brake and rear lights 15 Amp 2 Parking light 15 Amp 3 Flashing turn indicators clock 15 Amp 4 ...

Page 416: ...ng and avoid risk of abrasion Note the number and position of the cable straps Apply a thin coating of contact grease e g CENTOPLEX 3 CU to the central earth ground point which must be cleaned to bright metal first L Note When removing the wiring harness take out the central electrical equipment box at the same time When installing fit the central electrical equipment box first XTightening torque ...

Page 417: ...61 10 Installing wiring harness connections in central electrical equipment box RS610090 ...

Page 418: ...61 11 Installing wiring harness in central electrical equipment box output L Note The white marker tape arrow must be covered by the cable entry grommet RS610110 ...

Page 419: ...61 12 RT Wiring harness View from left 3 2 1 RT610160 ...

Page 420: ...61 13 1 RT610161 ...

Page 421: ...61 14 2 RT610162 ...

Page 422: ...61 15 3 RT610163 ...

Page 423: ...61 16 RT Wiring harness View from right 1 2 RS610170 ...

Page 424: ...61 17 1 RT610171 ...

Page 425: ...61 18 2 RT610172 ...

Page 426: ...61 19 RT Wiring harness at fairing holder RT610180 ...

Page 427: ...61 20 RT Wiring harness at instrument cluster RT610190 ...

Page 428: ...61 21 RS Wiring harness View from left 1 2 3 RS610040 ...

Page 429: ...61 22 1 RS610041 ...

Page 430: ...61 23 2 RS610042 ...

Page 431: ...61 24 3 RS610043 ...

Page 432: ...61 25 RS Wiring harness View from right 1 2 RS610030 ...

Page 433: ...61 26 1 RS610031 ...

Page 434: ...61 27 2 RS610032 ...

Page 435: ...61 28 RS Wiring harness at left switch unit RS610120 ...

Page 436: ...61 29 RS Wiring harness at right switch unit RS610130 ...

Page 437: ...61 30 GS Wiring harness View from left 1 2 3 GS610140 ...

Page 438: ...61 31 1 GS610141 ...

Page 439: ...61 32 2 GS610142 ...

Page 440: ...61 33 3 GS610143 ...

Page 441: ...61 34 GS Wiring harness View from right 2 1 GS610150 ...

Page 442: ...61 35 1 GS610151 ...

Page 443: ...61 36 2 GS610152 ...

Page 444: ...ive battery terminal first then pos itive terminal Reconnect positive battery terminal first then negative terminal Remove Motronic control unit ABS Remove control unit En caso necesario soltar el distribuidor de los cables de mando Remove the battery holder Install in the reverse order of work RS610010 ...

Page 445: ...ing and assembling instrument cluster 7 RS Removing and installing instrument cluster 8 RS Dismantling and assembling instrument cluster 8 GS Removing and installing instrument cluster 9 GS Dismantling and assembling instrument cluster 9 R Removing and installing instrument cluster 10 62 Instruments ...

Page 446: ...62 2 ...

Page 447: ...62 3 62 Technical Data R 1100 RS Instrument cluster Telltales for turn indicators high beam A 14 V 3 W Instrument lighting telltales A 12 V 1 7 W Speedometer drive Speedometer drive ratio I 2 6 ...

Page 448: ...62 4 Technical Data R 1100 RT Instrument cluster Telltales for turn indicators high beam A 14 V 3 W Instrument lighting telltales A 12 V 1 7 W Speedometer drive Speedometer drive ratio I 2 6 ...

Page 449: ... Data R 850 GS R 1100 GS Instrument cluster Telltales for turn indicators high beam A 14 V 3 W A 14 V 3 W Instrument lighting telltales A 12 V 1 7 W A 12 V 1 7 W Speedometer drive Speedometer drive ratio I 3 0 I 3 0 ...

Page 450: ...100 R Instrument cluster Telltales for turn indicators high beam A 14 V 3 W A 14 V 3 W Instrument lighting telltales A 12 V 1 7 W A 12 V 1 7 W Speedometer drive Speedometer drive ratio Cast wheel I 2 6 I 2 6 Spoked wheel I 3 0 I 3 0 ...

Page 451: ... Detach speedometer shaft Detach instrument cluster 1 and lift out of mount Disconnect plugs Install in the reverse order of work RT Dismantling and assembling instrument cluster Unscrew threaded connections at instruments 2 Detach trip distance recorder reset shaft 3 from speedometer Pull off instrument lighting Remove monitor unit 4 Assemble in the reverse order of work 1 4 2 3 RT620050 ...

Page 452: ...y from mount Detach speedometer shaft Disconnect plugs Install in the reverse order of work RS Dismantling and assembling instrument cluster Unscrew threaded connections at instruments 2 Pull off instrument lighting Remove monitor unit 3 Assemble in the reverse order of work eCaution When installing the speedometer note the grommet on the trip distance recorder reset button 1 3 2 RS620011 ...

Page 453: ...ach instrument cluster 2 Detach speedometer shaft Remove left cover Disconnect plugs Install in the reverse order of work GS Dismantling and assembling instrument cluster Unscrew threaded connections 3 at instrument cluster Pull off instrument lighting Remove monitor unit 4 Remove telltales Assemble in the reverse order of work GS620030 2 4 4 2 3 3 3 3 G62002 1 ...

Page 454: ...3 and right trims from instrument cluster Remove speedometer reset extension 7 Remove speedometer 4 Remove upper trim 5 from instrument cluster Pull off instrument lighting and telltales Detach cable strap at headlight Remove handlebar Remove headlight holder 6 Assemble in the reverse order of work 5 4 6 2 1 3 7 RS620040 ...

Page 455: ... Adjusting headlight 7 RS Removing and installing headlight 8 Adjusting headlight 8 GS Removing and installing headlight 9 Adjusting headlight 10 GS Removing and installing front flashing turn indicator 10 R Removing and installing headlight 10 Adjusting headlight 10 63 Lights ...

Page 456: ...63 2 ...

Page 457: ...S Headlight rectangular with halo gen bulb and manual beam throw adjustment Bulbs High beam low beam H 4 55 60 W halogen asymmetric Parking light 12 V 5 W Rear light 12 V 10 W Brake light 12 V 21 W Flashing turn indicator 12 V 21 W ...

Page 458: ...ca Data R 1100 RT Headlight rectangular with halogen bulb Bulbs High beam low beam H 4 55 60 W halogen asymmetric Parking light 12 V 5 W Rear light 12 V 10 W Brake light 12 V 21 W Flashing turn indicator 12 V 21 W ...

Page 459: ...alogen bulb rectangular with halogen bulb Bulbs High beam low beam H 4 55 60 W halogen asymmetric H 4 55 60 W halogen asymmetric Parking light 12 V 4 W 12 V 4 W Rear light 12 V 10 W 12 V 10 W Brake light 12 V 21 W 12 V 21 W Flashing turn indicator 12 V 21 W 12 V 21 W ...

Page 460: ...th halogen circular with halogen Bulbs High beam low beam H 4 55 60 W halogen asymmetric H 4 55 60 W halogen asymmetric Parking light 12 V 4 W 12 V 4 W Rear light 12 V 10 W 12 V 10 W Brake light 12 V 21 W 12 V 21 W Flashing turn indicator 12 V 21 W 12 V 21 W ...

Page 461: ... of fairing Remove headlight retaining screws arrows Remove headlight Install in the reverse order of work eCaution Do not touch inner surface of reflector or bulbs with bare hands Adjusting headlight Move swivel lever 1 to top position Correct the headlight beam throw with adjusting screw 2 Counter clockwise rotation longer Clockwise rotation shorter Adjustment distance 15 cm 5 91 in at a distanc...

Page 462: ...headlight at front section of fairing Detach windshield holder at headlight Remove headlight Install in the reverse order of work eCaution Do not touch inner surface of reflector or bulbs with bare hands Adjusting headlight Move swivel lever 1 to top position Correct headlight beam throw with adjusting screw 2 Counter clockwise rotation longer Clockwise rotation shorter Adjustment distance 15 cm 5...

Page 463: ...Insulate ground earth lead Remove windshield Remove headlight insert eCaution Do not touch inner surface of reflector or bulbs with bare hands Detach instrument cluster L Note The center retaining screw 1 is in the headlight housing Unfasten headlight beam throw adjuster Remove headlight housing RS630030 1 GS620020 ...

Page 464: ...cable through indicator holder eCaution Do not touch inner surface of reflector or bulbs with bare hands Remove turn indicator holder Remove indicators Install in the reverse order of work R Removing and installing head light eCaution Switch off ignition Disconnect ground earth lead from battery Insulate ground earth lead eCaution Do not touch inner surface of reflector or bulbs with bare hands Ad...

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