1994-2007 BMW R850C, R850R, R850GS, R1100R, R1100GS, R1100RS, R1100RT Motorcycle Workshop Repair & Service Manual (1,923 Pages,

BMW Motorcycle After Sales R 1100 RT R 1100 RS R 850/1100 GS R 850/1100 R Repair Manual

Published by: © BMW Motorcycle 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

Introduction This repair manual will help you to perform all the main maintenance and repair work correctly and efficient- ly. It should be consulted regularly by workshop personnel as an addition to the practical and theoretical knowledge obtained in Training School courses. It is a contribution towards achieving even higher Service quality. All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification. ● The repair manual is structured in the logical sequence of the work to be performed: Removal, Dis- assembly, Repair, Assembly, Installation. ● The entire contents are divided into individual chapters, corresponding 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. If the need arises, repair instructions are also issued in the form of Service Information. This information is of course incorporated into the next issue of the repair manual. We also recommend you to consult the detailed illustrations on the Parts microfiches as an additional source of information. BMW Motorcycle After Sales Published by: BMW Motorrad Hufelandstr. 6 D - 80937 München 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

00 Maintenance and general 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

34 Brakes 36 Wheels and tyres 46 Frame 51 Equipment 52 Seat 61 General electrical equipment 62 Instruments 63 Lights << Back >> Continuation Group / Chapter

Order No. 01 71 7 654 296 UX-VS-2, 03.99 Printed in Germany Customer Registration No. Order No. Signature of mechanic BMW Inspection 1000 km/ 600 mls BMW Service 10 000 km/6000 mls BMW Inspection 20 000 km/12 000 mls BMW Annual Service Change engine oil when engine is warm, renew oil filter cartridge 1) Change oil in manual transmission and rear wheel drive when at operating temperature Retighten cylinder head nuts Adjust valve clearance Check spark plugs Renew spark plugs Renew fuel filter 3) * ) Check battery acid level, if necessary top up with distilled water Clean and grease battery terminals Renew intake air cleaner 2) Check throttle cables for free movement, abrasion and kinking, renewing if necessary * ) Check clutch clearance, adjust if necessary Adjust Poly-V-belt [b SI 12 020 95 (700)] 4) 5) Retighten hose clips at intake pipe Check brake pads and discs for wear, renew if necessary * ) Check front/rear brake fluid level, top up if necessary * ) [b SI 00 027 95 (716)] Check brake system with regard to function, leaks; repair/renew as required * ) Renew brake fluid at least once a year Check wheel bearings, renew if necessary * ) Check swinging arm bearing (no play), adjust 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 bearing) Check idle speed, throttle synchronisation and CO value, adjust if necessary Final inspection with safety/operating check: – condition of tyres and wheels, rims and spokes, tyre pressures – lights and signal systems – telltale and warning lights – clutch and gear shift – handbrake and footbrake, steering – instruments – test ride, if necessary 1) for short-distance driving or outside temperatures below 0°C every 3 months, every 3,000 km (1,800 miles) at the latest 2) in very dirty or dusty conditions, renew the intake air cleaner element every 10,000 km (6,000 miles), or even more frequently if necessary 3) normally every 40,000 km (24,000 miles), but if fuel is of poor quality every 20,000 km (12,000 miles) 4) Renew Poly-V-belt every 40,000 km (24,000 miles) 5) After 60,000 km (36,000 miles), change the maintainance free Poly-V-belt, do not adjust *) invoiced as a separate item BMW AG Motorcycle Division Maintenance Schedule R1100RT/R1100RS/R850GS/R1100GS/R850R/R1100R

Order No. 01 71 7 654 296 UX-VS-2, 03.99 Printed in Germany Customer Registration No. Order No. Signature of mechanic BMW Pre-delivery check Inspect crates on receipt for signs of damage Motorcycle: – unpack – check scope of delivery – install/complete – clean Battery: – remove – add battery acid – charge – grease the terminal posts – re-install (mark date) Check complete specification delivery: – tools – handbooks and documents – 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 rear brakes – telltale and warning lights, instruments, lighting and signalling equipment – ABS – test ride, if necessary BMW AG Motorcycle Division Pre-delivery check R1100RT/R1100RS/R850GS/R1100GS/R850R/R1100R

B Order No. 01 71 9 799 171 UX-VS-1, 7/95 Printed in Germany Designation Data Measuring unit or specification Oilcapacities Engine (incl. filter) Engine (without filter renewal) Gearbox Rear wheel drive 3.75 5.50 fresh fill 1.0 change 0.8 fresh fill 0.25 change 0.23 litre litre [SI 11 048 90] Brand-name HD oil for petrol engines of API classi- fication SE, SF, SG; combination with CC or CD specification litre litre litre litre Valve clearance measured cold, i.e. at max. 35 °C E 0.15 / A 0.30 mm Ignition Static ignition disconnect at 6° b TDC Spark plugs Electrode gap limit of wear Bosch FR5DTC 0.8 1.0 mm mm Engine idle speed 1000 +150 1/min CO value (without catalytic converter) 1.5 ±0.5 Vol % Cable adjustment for increased cold starting speed (without cable junction) (with cable junction) throttle (without cable junction) gas cable (one piece) connecting cable throttle (with cable junction) gas cable (one piece) junction cable < 1 no backslash ca. 0.5 no backslash ca. 0.5 no backslash mm 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) Spark plugs Fuel tank to rear frame Fuel pump to tank Adjustable handle bars Quick release axle thread (axial) Quick release axle clamp Brake caliper Bearing bolt swingarm to gearbox/rear axle Idler bearing pin on swinging arm on gearbox/rear wheel drive Locknut Rear wheel retaining studs Tube clips to air intake pipe Screw connect. spring strut on control arm (RS with slide bearing) Tighten cylinder head – M 10 screw 11 32 23 23 8 8 20 8 20 22 6 20 30 22 front / rear 40 150 (Loctite 2701) 7 (Loctite 2701) 105 (Loctite 2701) 105 2 43 Thighten 20 180 40 Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm (clean thread) Nm (clean thread) Nm (clean thread) Nm Nm Nm (8.8 screw) Nm ° Torsion angle Nm BMW AG Motorcycle Division Service Data R 1100 RT/R 1100 RS/R 1100 GS/R 1100 R/R 850 R

00.1 Contents Page 00 Tightening torques R 1100 RS / R 1100 RT ....................................................................3 Tightening torques R 850/1100 GS und R 850/1100 R ........................................... 12 Operating materials ................................................................................................................... 21 Key to maintenance intervals ................................................................................................... 22 Change engine oil, renew oil filter element ................................................................. 22 (Inspection I, II, III, IV) ........................................................................................................................ 22 Change the oil in the gearbox and rear wheel drive ............................................... 23 (Inspection I, III, IV) ............................................................................................................................ 23 Changing oil in gearbox ............................................................................................................. 23 Changing oil in rear wheel drive ............................................................................................. 23 Checking battery acid level/topping up 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 belt (40 000 km/24 000miles) .......................................................................................................... 31 (renew maintenance-free belts every 60 000 km/36 000 miles) ......................................................... 31 Checking brake pads and discs for wear/renewing ............................................... 32 (Inspection III) .................................................................................................................................... 32 (ABS: Inspection II, III) ....................................................................................................................... 32 00 Maintenance and general instructions

00.2 Contents Page Checking brake pads for wear ................................................................................................ 32 Renewing brake pads – front brake ...................................................................................... 32 [RS] Renewing brake pads - rear brake .............................................................................. 33 [GS/R/RT] Renewing brake pads - rear brake ................................................................. 33 Checking brake discs for wear ............................................................................................... 33 Checking brake fluid level/topping up ............................................................................ 33 (Inspection III) .................................................................................................................................... 33 Bleeding/renewing the brake fluid using the handbrake lever/ brake pedaln ................................................................................................................................. 34 (Inspection III, IV) ............................................................................................................................... 34 Bleeding front brake circuit/renewing fluid ........................................................................ 34 Bleeding rear brake circuit/renewing brake fluid ............................................................ 34 Grease the centre stand [RS], side stand and clutch cable nipple ................ 35 (Inspection II, III, IV) ........................................................................................................................... 35 [RS] Cleaning and greasing the windshield adjusting shaft ............................... 35 (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 slack on hose clips at intake stub pipen ................................................ 37 (Inspection I, III) ................................................................................................................................. 37 Checking front wheel bearings/ checking tilt play at rear wheel .......................................................................................... 37 (Inspection III) .................................................................................................................................... 37 Checking swinging arm bearings, adjusting if necessary ................................... 37 (Inspection I, II, III) ............................................................................................................................. 37 Checking/adjusting throttle synchronisation and CO emission value .......... 38 (Inspection I, II, III, IV) ........................................................................................................................ 38 Final inspection with road safety and functional check ....................................... 42 (Inspection I, II, III, IV) ........................................................................................................................ 42

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1994-2007 BMW R850C, R850R, R850GS, R1100R, R1100GS, R1100RS, R1100RT Motorcycle Workshop Repair & Service Manual (1,923 Pages,

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