Repair Manual

R 1100 RT
R 1100 RS
R 850/1100 GS
R 850/1100 R

BMW Motorcycle
After Sales

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 efficiently. It should be consulted regularly by workshop personnel as an addition to the practical and theoretical
knowledge obtained in Training School courses. It is a contribution towards achieving even higher Service
quality.

All information in both text and illustrations refers to motorcycles in standard condition or with genuine
BMW accessories installed, and not to motorcycles which have been modified in any way to depart from
the manufacturer’s specification.
● The repair manual is structured in the logical sequence of the work to be performed: Removal, Disassembly, Repair, Assembly, Installation.
● 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

Contents
<< Back
Group / Chapter

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

>> Continuation
Group / Chapter

34 Brakes

36 Wheels and tyres

46 Frame

51 Equipment

52 Seat

61 General electrical equipment

62 Instruments

63 Lights

<< Back

Signature of mechanic

Change engine oil when engine is warm, renew oil filter cartridge

BMW
Annual Service

Order No.

BMW Inspection
20 000 km/12 000 mls

Registration No.

BMW Service
10 000 km/6000 mls

Customer

BMW Inspection
1000 km/ 600 mls

BMW AG Motorcycle Division
Maintenance Schedule
R 1100 RT/R 1100 RS/R 850 GS/R 1100 GS/R 850R/R 1100 R

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

Order No. 01 71 7 654 296

UX-VS-2, 03.99

Printed in Germany

BMW AG Motorcycle Division
Pre-delivery check
R 1100 RT/R 1100 RS/R 850 GS/R 1100 GS/R 850R/R 1100 R
Customer

Registration No.

BMW
Pre-delivery check

Order No.

Signature of mechanic

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

Order No. 01 71 7 654 296

UX-VS-2, 03.99

Printed in Germany

BMW AG Motorcycle Division
Service Data
R 1100 RT/R 1100 RS/R 1100 GS/R 1100 R/R 850 R
Designation

Data

Oilcapacities
Engine (incl. filter)
Engine (without filter renewal)

B

Measuring unit or
specification

3.75
5.50

litre
litre
[SI 11 048 90]
Brand-name HD oil for
petrol engines of API classification SE, SF, SG;
combination with CC or CD
specification

Gearbox

fresh fill
change

1.0
0.8

litre
litre

Rear wheel drive

fresh fill
change

0.25
0.23

litre
litre

Valve clearance
measured cold, i.e. at max. 35 °C

E 0.15 / A 0.30

Ignition
Static ignition

disconnect at
6° b TDC

Spark plugs
Electrode gap
limit of wear

Bosch FR5DTC
0.8
1.0

Engine idle speed

mm

mm
mm

1000 +150

1/min

1.5 ±0.5

Vol %

<1
no backslash

mm play

throttle (without cable junction)
gas cable (one piece)
connecting cable

ca. 0.5
no backslash

mm play

throttle (with cable junction)
gas cable (one piece)
junction cable

ca. 0.5
no backslash

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

CO value (without catalytic converter)
Cable adjustment
for increased cold starting speed

(without cable junction)
(with cable junction)

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
Order No. 01 71 9 799 171

UX-VS-1, 7/95

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
Printed in Germany

00

00 Maintenance and general instructions

Contents

Page

Tightening torques R 1100 RS / R 1100 RT

....................................................................3

Tightening torques R 850/1100 GS und R 850/1100 R
Operating materials

...........................................12

...................................................................................................................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

00.1

...................................................38 (Inspection I................................................................. II...................................................................... III) ................................ IV) ..................................................... II....................................................................................................................................34 Bleeding front brake circuit/renewing fluid .............................................................. adjusting if necessary ................................................................................................33 Checking brake fluid level/topping up ....35 Checking/adjusting clutch operating clearance ...35 (Inspection II...............................34 (Inspection III.........................................................37 Checking swinging arm bearings.........................................................................................................................42 00.....................................................................................................35 [RS] Grease front suspension strut at its lower attachment lug (version with plain bearing only) ...........2 ........... IV) .....................................................................................................34 Bleeding rear brake circuit/renewing brake fluid .............37 Checking front wheel bearings/ checking tilt play at rear wheel ..........................33 .....................................................................................37 (Inspection I) .........................37 (Inspection I) .................................................32 Renewing brake pads – front brake ........................................................................................................................................................................................ side stand and clutch cable nipple ...................................................................37 [RS] Check tightness of screws at adjustable handlebar ...............................................................37 (Inspection III) ....36 Checking tightness of rear wheel studs ................................................... III....................................37 Checking/adjusting throttle synchronisation and CO emission value ..................42 (Inspection I.38 Final inspection with road safety and functional check .................... IV) ................................................33 (Inspection III) ...........................................................................................................................37 (Inspection II........................................................................................................................................... II.................. III...........35 (Inspection II..................................37 Taking up slack on hose clips at intake stub pipen ...................34 Grease the centre stand [RS]........................................................................................................................................................................................................................................................................ III) ...................................................Contents Checking brake pads for wear Page ............................................................................................................................................................................................32 [RS] Renewing brake pads ............. IV) ........................ II...................35 (Inspection III) .......................................................................................................................37 (Inspection I... III) ........35 [RS] Cleaning and greasing the windshield adjusting shaft ....................................................... III....................rear brake ...................................rear brake Checking brake discs for wear ................................................. III) ..........................................33 [GS/R/RT] Renewing brake pads ....................37 [R] Check steering damper ................33 Bleeding/renewing the brake fluid using the handbrake lever/ brake pedaln ...............................................................36 (Inspection I........................................................................................................................37 (Inspection I.................. III) ........................

Tighten cylinder head nuts (oiled) crosswise 1. Unfasten one nut 2. Tighten one nut to initial value 3. M 6 screw 9 9 20 20 4.1 Tighten all nuts to correct torque for joint 1. 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 Chain sprocket to camshaft 65 65 Camshaft bearing cap 15 15 M 8 screw 20 20 Banjo screw 25 25 M 6 screw 9 9 M 8 screw 20 20 Chain sprocket to crankshaft 10 10 Chainwheel to auxiliary shaft 70 70 Chain tensioner housing to engine block 9 9 11 Engine Connection Cylinder head Tightening sequence: 1.00 Tightening torques R 1100 RS / R 1100 RT Model R 1100 RS R 1100 RT Nm Nm 20 20 2.2 Tighten all nuts to correct angle 90° 1.3 . Tighten nut to wrench angle 180° Camshaft Rotary breather Vent line to alternator mount cover Alternator mount cover Auxiliary shaft 00. tighten cylinder head nuts crosswise: 1. M 10 screw 40 40 3.3 Tighten all nuts to correct angle 90° After 1000 km.

banjo screw 25 25 Cooling oil line .4 .banjo screw with oil vent valve 25 25 Oil lines to oil cooler 25 – Oil cooler to holder 9 9 Oil cooler return line 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 Oil cooler hose at oil thermostat – 40 M 8 screw 20 20 M 6 screw 9 9 Chain guide rail pivot screw 18 18 32 32 20 20 M 10 screw (oiled) 45 45 M 8 screw (oiled) 20 20 M 6 screw 9 9 11 Engine Connection Oil filter Oil pump Oil cooler Clean threads and apply Loctite 603 to inner and outer threads and in the contact face area Cylinders Tightening sequence Timing chain Chain tensioner Connecting rod Big end cap Joint torque Additional wrench angle 80° Crankcase Tightening sequence: 00.Model R 1100 RS R 1100 RT Nm Nm Oil filter 11 11 Oil drain plug 32 32 Mesh filter basket to engine block 9 9 Oil pump cover 9 9 Pressure relief valve 35 35 Oil pressure switch 30 30 Oil cooler pipe to engine block 10 10 Cooling oil line .

5 .Model R 1100 RS R 1100 RT Connection Nm Nm Starter motor to engine 20 20 Starter cover to gearbox housing 7 – Positive lead to starter motor 10 10 Alternator to alternator support cover 20 20 Tensioning and retaining strap at alternator 20 20 Spacer at alternator 20 20 Positive lead to alternator 15 15 Belt pulley at alternator 50 50 Belt pulley to crankshaft 50 50 Poly-V belt preload 8 8 Spark plug 20 20 25 25 Fuel tank to rear frame 22 22 Fuel pump assembly to tank 6 6 Muffler to footrest 35 35 Manifold to cylinder head (with strap) 22 22 18 18 Muffler to support plate for center stand 20 20 Clip on muffler 50 50 12 Engine electrical system 13 Fuel preparation and control Temperature sensor on engine block 16 Fuel tank and lines 18 Exhaust system (with jacket pipe) Grease clamping face with Never Seez Oxygen sensor (lambda probe) to muffler 55 55 Grease with Never Seez 00.

Model R 1100 RS R 1100 RT Nm Nm 40 40 21 Clutch Connection Clutch housing Joint torque oil screw threads lightly Additional wrench angle 32° Housing cover 18 18 Locknut on release lever 22 22 Oil filler plug 23 23 Oil drain plug 23 23 Gearbox cover to gearbox housing 9 9 Screw for neutral detent 13 13 23 Gearbox 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 gearbox 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 00.6 .

Model R 1100 RS R 1100 RT Connection Nm Nm Clamp between fixed tubes and fork bridge 22 – Screw connection between fixed tube and fork bridge – 45 (free from oil and grease) Control arm to ball joint 130 130 31 Front fork clean thread + Loctite 2701 Fork bridge to ball joint 130 – clean threads + Loctite 2701 – – 130 – clean threads + Loctite 243 fork slider tube bridge 230 230 Frame 230 – 22 – clean thread + Loctite 243 – Screw plug to fixed fork tube 18 pressed fit. do not release Clamping screws.9 screw Handlebar at rubber mount 40 – Rubber mount at fork bridge 40 – Handlebar to fork bridge – 21 Twistgrip to handlebar 7 7 Handlebar weight to fixed handlebar 20 – Handlebar weight to handlebar – 20 Handlebar weight to adjustable handlebar 7 7 clean threads + Loctite 2701 – 32 Steering 00.9 screw 50 10. quick-release axle 22 22 right 73 73 left 42 42 Threaded journal to frame Ball joint to Slider tube bridge to slider tube Control arm to engine Screw cap apply light coat of Never Seez to thread Spring strut to frame 47 47 Spring strut to control arm 43 8.8 screw 43 8.7 .8 screw 50 10.

85 kg and tighten loose strut Spring strut to rear frame / rear swinging arm Hydraulic spring adjuster at footrest plate 00. input bevel gear 200 33 Rear wheel drive 200 clean thread + Loctite 273 Housing cover 35 35 Fixed bearing journal Swinging arm to gearbox/ Swinging arm at rear 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.9 screw 50 10.8 screw 50 10.8 43 8.9 screw – 22 .Model R 1100 RS R 1100 RT Connection Nm Nm Oil drain plug 23 23 Oil filler plug 23 23 Threaded ring 118 (Hylomar SQ 32 M) 118 (Hylomar SQ 32 M) Hexagon nut.8 screw 43 8.

front/rear 15 15 Brake hose to fitting 15 15 Brake hose to flow distributor 15 15 Flow distributor to frame 9 9 Flow distributor to slider tube bridge 9 9 Flow distributor to holder/slider tube – 9 Bleed screw on 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 necessary ABS sensor 4 (handtight) 4 (handtight) M6 screw 9 9 M6 screw (Torx) 5 5 Brake line to ABS unit 15 15 Bleed screw to ABS unit 9 9 Clamping screws. then tighten crosswise: 00.9 .Model R 1100 RS R 1100 RT Connection Nm Nm Brake caliper to slider tube 40 40 Brake caliper to rear wheel drive 40 40 Brake disc to front wheel 21 21 Brake disc to rear wheel drive 21 21 34 Brakes clean thread + Loctite 273 Brake hose to brake caliper. quick-release axle 22 22 Screw connection. quick-release axle 30 30 Initial tightening 50 50 Final tightening 105 105 ABS unit to holder 36 Wheels and tyres Screw on wheel nuts handtight.

Model R 1100 RS R 1100 RT Connection Nm Nm Rear frame to gearbox/engine 47 47 Footrest plate to gearbox 22 22 Frame to engine 82 82 Struts to frame 47 8.9 screw Struts to engine 47 47 Guard hoop to cylinder head 20 20 Side stand to pivot mount 42 42 46 Frame Screw connection on right of gearbo at right of engine at left of engine at left of gearbox 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 M 6 screw 9 – M 8 screw 21 21 M 10 screw 42 – Footrest to footrest plate 42 – Fairing support bracket to frame 20 20 Footrest plate to rear frame 00.8 screw 58 10.8 screw 47 8.9 screw 58 10.10 .

11 .Model R 1100 RS R 1100 RT Connection Nm Nm Ignition/steering lock to fork bridg 15 15 Horn to horn bracket 8 20 Ground (earth) strap to engine block 10 10 Rubber bushing for battery holder at gearbox 4 4 51 Equipment 61 General electrical system 00.

2 Tighten all nuts to correct angle 90° 1.3 Tighten all nuts to correct angle 90° After 1000 km.Tightening torques R 850/1100 GS und R 850/1100 R Model R 850/1100 GS R 850/1100 R Nm Nm 20 20 2. M 6 screw 9 9 20 20 4.1 Tighten all nuts to correct torque for joint 1. Tighten nut to wrench angle 180° Camshaft Rotary breather Vent line to alternator mount cover Alternator mount cover Auxiliary shaft 00. tighten cylinder head nuts crosswise: 1. Tighten one nut to initial value 3.12 . Unfasten one nut 2. 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 Chain sprocket to camshaft 65 65 Camshaft bearing cap 15 15 M 8 screw 20 20 Banjo screw 25 25 M 6 screw 9 9 M 8 screw 20 20 Chain sprocket to crankshaft 10 10 Chainwheel to auxiliary shaft 70 70 Chain tensioner housing to engine block 9 9 11 Engine Connection Cylinder head Tightening sequence: 1. Tighten cylinder head nuts (oiled) crosswise 1. M 10 screw 40 40 3.

banjo screw with oil vent valve 25 25 Oil lines to oil cooler 25 – Oil cooler to holder 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 11 Engine Connection Oil filter Oil pump Oil cooler Clean threads and apply Loctite 603 to inner and outer threads and in the contact face area Cylinders Tightening sequence: 1. M 10 screw (oiled) 45 45 2. M 6 screw 9 9 Timing chain Chain tensioner Connecting rod Big end cap Joint torque Additional wrench angle 80° Crankcase Tightening sequence: 00. M 8 screw 20 20 2.13 .Model R 850/1100 GS R 850/1100 R Nm Nm Oil filter 11 11 Oil drain plug 32 32 Mesh filter basket to engine block 9 9 Oil pump cover 9 9 Pressure relief valve 35 35 Oil pressure switch 30 30 Oil cooler pipe to engine block 10 10 Cooling oil line . M 8 screw (oiled) 20 20 3. M 6 screw 9 9 3. Chain guide rail pivot screw 18 18 32 32 20 20 1.banjo screw 25 25 Cooling oil line .

14 55 .Model R 850/1100 GS R 850/1100 R Connection Nm Nm Starter motor to engine 20 20 Starter cover to gearbox housing 7 7 Positive lead to starter motor 10 10 Alternator to alternator support cover 20 20 Tensioning and retaining strap at alternator 20 20 Spacer at alternator 20 20 Positive lead to alternator 15 15 Belt pulley at alternator 50 50 Belt pulley to crankshaft 50 50 Poly-V belt preload 8 8 Spark plug 20 20 25 25 Fuel tank to rear frame 22 22 Fuel pump assembly to tank 6 6 Strut to tank – 15 24 24 (with strap) 22 22 (with jacket pipe) 18 18 Muffler to support plate for center stand 20 20 Clip on muffler 50 50 12 Engine electrical system 13 Fuel preparation and control Temperature sensor on engine block 16 Fuel tank and line 18 Exhaust system Muffler to rear frame Manifold to cylinder head Grease clamping face with Never Seez Oxygen sensor (lambda probe) to muffler 55 Grease with Never Seez 00.

Model R 850/1100 GS R 850/1100 R Nm Nm 40 40 21 Clutch Connection Clutch housing Joint torque oil screw threads lightly Additional wrench angle 32° Housing cover 18 18 Locknut on release lever 22 22 Oil filler plug 23 23 Oil drain plug 23 23 Gearbox cover to gearbox housing 9 9 Screw for neutral detent 13 13 23 Gearbox 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 gearbox 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 00.15 .

9 screw Steering damper to fork slider bridge mount – 20 clean thread + Loctite 2701 Steering damper mount to fork slider bridge – 9 clean thread + Loctite 2701 Steering damper to leading link pivot mount – 20 clean thread + Loctite 2701 Steering damper pivot mount at leading link – 20 Joint head against locknut – 20 00. do not release! Clamping screws. quick-release axle 22 22 right 73 73 left 42 42 Control arm to engine Screw cap apply light coat of Never Seez to thread Spring strut to frame 47 47 Spring strut to control arm 50 10.Model R 850/1100 GS R 850/1100 R Connection Nm Nm Screw connection between fixed tube and fork bridge 45 (free from oil and grease) 45 (free from oil and grease) Control arm to ball joint 130 130 31 Front fork clean thread + Loctite 2701 Threaded journal to frame 130 130 clean threads + Loctite 243 Ball joint to fork slider tube bridge Slider tube bridge to slider tube 230 230 22 22 clean threads + Loctite 243 Screw plug to fixed fork tube press fit.16 .9 screw 50 10.

17 . 85 kg and tighten loose strut) Spring strut to rear frame / rear swinging arm 50 10.9 screw Hydraulic spring adjuster at footrest plat 22 – 00. input bevel gear 200 32 Steering 33 Rear wheel drive 200 clean thread + Loctite 273 Housing cover 35 35 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.9 screw 50 10.Model R 850/1100 GS R 850/1100 R Connection Nm Nm Handlebar to fork bridge 21 21 Twistgrip to handlebar 7 7 Handlebar weight to fixed handlebar 20 20 Oil drain plug 23 23 Oil filler plug 23 23 Threaded ring 118 (Hylomar SQ 32 M) 118 (Hylomar SQ 32 M) Hexagon nut.

Model R 850/1100 GS R 850/1100 R Connection Nm Nm Brake caliper to slider tube 40 40 Brake caliper to rear wheel drive 40 40 Brake disc to front wheel Cast wheel Spoked whee – 24 21 24 34 Brakes clean thread + Loctite 243 Brake disc to rear wheel drive 21 21 clean thread + Loctite 273 Brake disc to rear wheel 21 21 clean thread + Loctite 243 Brake hose to brake caliper.18 . front/rear 15 15 Brake hose to fitting 15 15 Brake hose to 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 times if necessary) ABS sensor 4 (handtight) 4 (handtight) M6 screw 9 9 M6 screw (Torx) 5 5 Brake line to ABS unit 15 15 Bleed screw to ABS unit 9 9 ABS unit to holder 00.

at left of gearbox 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 Footrest plate to rear frame M 8 screw Fairing support bracket to frame 21 21 20 – 00.9 screw 58 10. then tighten crosswise: 46 Frame Rear frame to gearbox/engine 1.9 screw Struts to engine 58 58 Guard hoop to cylinder head 20 20 Side stand to pivot mount 42 42 36 Wheels and tyres Screw on wheel nuts handtight. at right of engine 3. at left of engine 4.Model R 850/1100 GS R 850/1100 R Connection Nm Nm Clamping screws. quick-release axle 22 22 Screw connection. quick-release axle 30 30 Initial tightening 50 50 Final tightening 105 105 47 47 Footrest plate to gearbox 22 22 Frame to engine 82 82 Struts to frame 47 8.8 screw 47 8.19 . Screw connection on right of gearbox 2.8 screw 58 10.

Model R 850/1100 GS R 850/1100 R Connection Nm Nm Ignition/steering lock to fork bridge 15 15 Horn to horn bracket 8 8 Ground (earth) strap to engine block 10 10 Rubber bushing for battery holder at gearbox 4 4 51 Equipment 61 General electrical system 00.20 .

heavy Damping grease 07 58 9 058 193 10 g tube Retinax A (Taper) roller bearing grease 81 22 9 407 710 100 g tube Contact spray Contact spray 81 22 9 400 208 300 ml aerosol 3-Bond 1209 Surface sealant 07 58 9 062 376 30 g tube Loctite 574 Surface sealant 81 22 9 407 301 50 ml tube Curil K 2 Heat-conductive sealant 81 22 9 400 243 250 g can Hylomar SQ 32 M Permanently elastic sealant 81 22 9 400 339 100 g tube Lubricant Sealants Adhesives and retaining agents Loctite 648 Structural adhesive. strong 81 22 9 400 086 10 ml bottle Loctite 2701 Thread retainer 33 17 2 331 095 10 ml bottle Loctite 454 Cyanacrylate adhesive 07 58 9 062 157 20 g tube 3-Bond 1110 B Joint adhesive 07 58 9 056 998 5 g tube Brake cleaner 81 22 9 407 704 600 ml aerosol Penetrant MR 68 Crack testing agent for aluminum housings 81 22 9 407 494 500 ml spray Entwickler MR 70 Developer for aluminum housing crack testing agent 81 22 9 407 495 500 ml spray Cleaner Brake cleaner Testing agent 00. medium-strength 07 58 9 056 031 10 ml bottle Loctite 270 Thread retainer.21 .Operating materials Item Use Order number Quantity Optimoly MP 3 High-performance lubricating paste 07 55 9 062 476 100 g tube Optimoly TA High-temperature assembly paste 18 21 9 062 599 100 g tube Silicone grease 300. 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.

.. Fit new seal and screw in drain plug.Key to maintenance intervals – – – – Inspection at 1000 km (600 miles) BMW Service BMW Inspection Annual Service I II III IV Change engine oil.50 l (6... unscrew and remove the oil filter element..... III.. Coat sealing ring on new oil filter element with oil and screw in... Do not check oil level until at least 10 minutes after test run/test ride......... pints) ..88 Imp....SG..75 l (6....... API classifications SE................ IV) Max Min 11 4 650 RS110950 RS000180 • • • Remove screw plug.... e Caution: Never add engine oil above the MAX mark. BMW No.........3.....0. Unscrew oil drain plug and drain off oil.22 ............. pints) Oil volume between MIN and MAX marks ..6 Imp.. Top up oil/seal off...... II.....3... 11 4 650...50 l (0.......with oil filter change ....without oil filter change .... X Tightening torque: Oil filter...............SF.... 00. renew oil filter element (Inspection I.... pints) Engine oil grade: Brand-name HD oil for four-stroke spark-ignition engine. 32 Nm Fill quantity for engine: .....2 Imp.. • • • • Using oil filter wrench.... combination with CC or CD specification...... 11 Nm Oil drain plug..

...8 l (1........... Insert oil filler plug with new seal........ Top up gearbox oil............... IV) Changing oil in gearbox RT 1 RS000070 • RS000210 • • • • • [RT] Push in oil drain pipe (1).. pints) During oil changes .............. Insert oil filler plug with new seal....0 l (1.... X Tightening torque: Oil drain plug................. 23 Nm Oil filler plug . 23 Nm Fill quantity: Initial filling .....................1... SAE 90........ 23 Nm Oil filler plug .. Top up gearbox oil..0......76 Imp...... Fit new seal and screw in drain plug............4 Imp...........0...0..44 Imp................ pints) Oil grade: Brand-name hypoid gear oil...... 23 Nm • • • Unscrew and remove oil filler plug and oil drain plug/drain off oil. Fit new seal and screw in drain plug.23 l (0............ pints) During oil changes .............Change the oil in the gearbox and rear wheel drive Changing oil in rear wheel drive (Inspection I... III... 23 4 680 and turn to right.... X Tightening torque: Oil drain plug. Unscrew and remove oil filler plug and oil drain plug/drain off oil........ API class GL 5 Fill quantity:: gearbox up to lower rim of filler hole Initial filling.......................404 Imp........ pints) 00....23 ......................... BMW No.......................25 l (0......

....... [RS/RT] Take off left side fairing.. cleaning/greasing battery posts (Inspection III.3 1 RS 2 R/GS/RT RS000340 Checking battery acid level/topping up if necessary. X Tightening torque: Fuel tank to rear frame . [GS] Take off right side fairing............... 22 Nm 00..... Remove air cleaner cover (1)... [GS/R] Unscrew fuel tank fastenings. Release the rubber battery strap (3)... raise it and support it with a suitable object. IV) • • • • • • • • • • Remove dualseat. Connect positive battery terminal first.. • • Top up battery acid level with distilled water as far as the MAX mark. [GS] Detach fuel tank at rear... 22 Nm .. Remove battery......g.... Installation in reverse order...24 Renewing air cleaner (Inspection III) • • • Remove dualseat.... Protective battery-post grease: e....... Remove intake air pipe (2).. then negative terminal.... [R] Remove tank cover... then positive terminal... e Caution: Disconnect negative terminal of battery first. Renew air cleaner insert.. Bosch Ft 40 V1 X Tightening torque: Fuel tank to rear frame .. [GS/R] Raise rear of fuel tank and support with a suitable object..

BMW No. [RT] Detach storage compartment • • • • • Unfasten fuel tank mount (2) Seal off fuel feed and return line (3) with hose clip. [R] Remove fuel tank cover.25 . Lift off fuel tank. loosen and pull off. Remove fuel pump connector (5). [RS] Detach cockpit inner panel (1) at fuel tank.RS 4 1 13 3 010 5 3 2 RS160010 Renewing fuel filter (Inspektion III) • • • • • • Remove dualseat. 00. Remove vent pipes (4). [RS/RT] Take off side sections of fairing. [GS] Remove right side fairing. 13 3 010.

RT 6x C B A 13 3 010 3 4 B A C 5 6x RT160060 00.26 .

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

... 22 Nm Fuel pump unit to fuel tank .... X Tightening torqu Fuel tank to rear frame ..... e Caution: Note correct direction of flow through fuel filter... 13 1 500. ...28 ...... After assembly.... Installation in reverse order. check fuel pump unit for leaks............ BMW No.. Use only an O-ring seal (2) in good condition..... 6 Nm 00.1 2 RS160030 • • • • Detach hoses from fuel filter (1) Fit new fuel filter...... Secure non-reusable hose clips with pliers................

. 180° 2........ or set the piston to TDC by turning the belt pulley. e Caution: Trap escaping oil... 12 3 510. TDC RS000010 • • Pull off spark plug cap with cap assembly tool... torque ......Checking/renewing spark plugs Taking up slack at cylinder heads (Inspection II... 1........ 20 Nm 1.. Tighten cylinder head nuts individually in a crosswise pattern 1. • Tighten cylinder head nuts...........0 mm (0.. Unscrew and remove spark plugs with sparkplug wrench. Electrode gap: .. 0....Tighten nut to init...04 in) e Caution: RS00002 • RS 00.. the inlet and exhaust valves of the cylinder in question are closed...... Tightening procedure after 1000 km ( 600 miles ) 1.1. BMW No.risk of breakage! Top dead centre on ignition stroke: 1.... III) (Inspection I) • 12 3 510 Remove cylinder head cover...........2....... Do not bend electrodes . BMW No..... 40 Nm 00...3. The OT (TDC) mark appears and 2...Tighten nut to specified wrench angle..0315 in) Gap wear limit:..29 ....8 mm (0. 12 3 520..Slacken off one nut 1... 002 Select a gear and turn the rear wheel.. Unfasten/retighten M10 screw .........

............ III) RS110980 • Check valve clearance with feeler gauge and......30 mm (0.................................. Adjust valve clearances with the engine cold (max... if necessary........................ 20 Nm 00...15 mm ( 0... Assemble in reverse order e Caution: Make sure that gasket is correctly seated.......012 in ) X Tightening torque: Locknut .......... correct with adjusting nut/lock.... Gaskets and sealing faces must be free from oil or grease X Tightening torqu Cover screw .. 8 Nm Spark plug (without lubricant) ........ II......................30 ........ 0.................Checking/adjusting valve operating clearances (Inspection I............ 0........... 35°C): Inlet .006 in) Exhaust ....... it must be possible to insert the feeler gauge between valve stem and rocker with only slight resistance to movement.................... 8 Nm • • Check valve clearance again...........

.... Slacken off alternator mounting screws (1.. • X Tightening torque: Poly-V belt preload... fully tighten retaining nut (3)........ RS110490 • • • • [RS/RT] Remove left side fairing......4) and install a new Poly-V belt if necessary....... II.. then release belt tension... 00... 20 Nm L Note: aSee also Service Information 12 020 95 (700). [R] Remove left fuel tank cover. 8 Nm Alternatorto alternator support cover.. III) Renewing Poly-V belt (40 000 km/24 000miles) (renew maintenance-free belts every 60 000 km/ 36 000 miles) 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..... (Inspection I.31 . slacken adjusting screw and tighten screws fully..... tension it and turn the engine over once. Remove front cover..3..........3 2 4 1 RS110480 Adjusting Poly-V belt Poly-V belt adjusting procedure: Poly-V belt installation procedure: • Place the Poly-V belt in position...

Remove brake pads by pulling downwards. 34 1 500. .. 1. III) Checking brake pads for wear 1 RS340020 • LT000090 • Unfasten/remove brake caliper. Drive out retaining pin (1).. push the pistons back fully with resetting tool. mask it off with tape if necessary [RS] Measure brake pad thickness (arrows)... 40 Nm .. • • • Remove keeper from retaining pin (1). e Caution: Brake pad thickness must not fall below the minimum value...32 LT000100 • • Before installing the brake caliper. 34 1 500 GS000390 • [GS/R/RT] Check wear marks.Checking brake pads and discs for wear/renewing Renewing brake pads – front brake (Inspection III) (ABS: Inspection II...... X Tightening torque: Brake caliper to rear wheel drive ..... Change pads only as a complete set...... BMW No...5 mm (0. e Caution: [RS/R/RT] Do not scratch the wheel rim.. Minimum lining thickness: . Install in the reverse order of work.059 in) 00.

....181 in) Checking brake fluid level/topping up (Inspection III) Max... damage. working from the wheel side.... Brake fluid grade: Use only brake fluid of DOT 4 quality classification (e.. Min......rear brake Checking brake discs for wear 1 LT000120 • • • • • Lever off cap from brake caliper... distortion. If necessary.... wear and scoring... 4... Before installing the brake caliper.. BMW No. Fit diaphragm and reservoir cover.[RS] Renewing brake pads . Unfasten/remove brake caliper.. Carefully tighten retaining screws... Remove brake pads. RS000160 GS000400 • • • • • • • [RT] Take out the rear wheel. 34 1 500.. depress the piston fully..33 ..... push pistons fully back with resetting tool....6 mm (0... Lift brake pads upwards to remove. Install in the reverse order of work. Min.g... 4....rear brake LT000110 • Carefully inspect brake discs for cracking. Drive out retaining pins (1)... • • • • Remove reservoir cover together with diaphragm.. Add brake fluid up to the MAX mark. [GS/R/RT] Renewing brake pads .... Brake disc wear limit:.... 40 Nm 00.177 in) [RS] rear:.. 1 Max.. Drive out retaining pin (1) towards the wheel side. Remove keeper from retaining pin (1).. Install in the reverse order of work. ATE "SL“ brake fluid) X Tightening torque: Brake caliper at rear wheel drive: ......5 mm (0......

Do not tilt the brake calipers when removing. Connect a vessel to the brake caliper to trap brake fluid as it emerges from the bleed screw. e Caution: • • Caution: Do not release the lever/pedal until the bleed screw has been closed. then open bleed screw while maintaining firm pressure on the handbrake lever. After this. Brake fluid level = MAX mark. BMW No. slacken off the bleed plug by a half-turn. slacken off the brake caliper and position it so that the bleed nipple is at the highest point. Press the pistons back in the second brake caliper. repeat the bleeding operation. There is a risk of dmage to the brake pads. Close bleed screw. Fit diaphragm and reservoir cover. IV) Bleeding front brake circuit/renewing fluid • • • Remove front brake pads. 34 1 500. 00. Add brake fluid up to the MAX mark. • Unscrew brake fluid reservoir cover and remove together with diaphragm.Bleeding/renewing the brake fluid using the handbrake lever/brake pedaln (Inspection III. and leave the resetting tool in position. Maintain pressure on handbrake lever. Install brake pads/brake calipers. Carefully tighten retaining screws. If this occurs. brake fluid level must not drop below the MIN mark. Turn handlebar from lock to lock. BMW No.34 [RS/GS] The rear brake caliper does not have to be removed. [R/RT] To bleed. 34 1 520. or else air will be drawn into the brake system. the procedure is the same as for bleeding/renewing the front brake fluid. Allow brake fluid to emerge from both brake calipers in succession until it is clear and free from bubbles. • Close bleed screw and release handbrake lever. e e Caution: • • • • • • • • • During the bleeding process. Apply handbrake lever several times until brake pressure can be detected. in its place. Bleeding rear brake circuit/renewing brake fluid 34 1 500 • • • LT000100 • • Press the brake pistons fully back with the piston resetting tool. nor the pistons pushed back. actuating brake several times while doing so. Perform a functional check on the brake system. Remove the piston resetting tool and insert spacer. .

..g.... Shell Retinax A [RS] Grease front suspension strut at its lower attachment lug (version with plain bearing only) (Inspection II.....35 .........g.... e... IV) (Inspection III) RS000360 RS000330 • Clean and grease the nipple with a grease gun until grease starts to emerge at the bearing point............. e............. Never Seeze X Tightening torque: RS330320 Spring strut to control arm ....g.......... III............ clean and grease the shaft.. Lubricant:.......Grease the centre stand [RS].. side stand and clutch cable nipple [RS] Cleaning and greasing the windshield adjusting shaft (Inspection II........... then screw it back in.. e... e................................ Shell Retinax A 00.... 43 Nm Lubricant:.. III) Lubricant:..... Lubricant:..... Staburags NBU 30 PTM • Unscrew.g........

..Checking/adjusting clutch operating clearance (Inspection I... [RT] Slacken off the power socket holder..276 in) X Tightening torque: Locknut on adjusting screw .... BMW No........... II..........472 in) Distance B: ........ using the adjusting screw on the release lever. 31 5 600. BMW No....... slacken off locknut (1) at adjusting screw (2) on the clutch release lever/gearbox.0 mm (0.. III) B A RS210020 • RS210040 • Set distance A at the adjusting screw.. Set to distance B at the handlebar clutch lever...... Using socket wrench........... 7. 21 3 610.... 22 Nm 21 21 3 610 RS210030 • • • [GS] If necessary.... 00...... 12 mm (0.36 ........... slacken off hydraulic spring adjuster with 6 mm Allen key.......... Distance A:.

........ (Inspection I) Checking swinging arm bearings..Checking tightness of rear wheel studs Checking front wheel bearings/ checking tilt play at rear wheel (Inspection I) (Inspection III) X Tightening torque: • • • • Rear wheel nuts .............. If play is detected in the wheel bearings. RS000350 X Tightening torque: Handlebar adjusting screw ... bracing against the frame. 2 Nm 00.. adjusting if necessary (Inspection I........ 20 Nm [R] Check steering damper (Inspection II.... renew them..... Taking up slack on hose clips at intake stub pipen (Inspection I. Tilt the front wheel to and fro across the axle. If play is detected....................... III) X Tightening torque: Hose clips on air intake pipe .... III) • • – Freedom from play at ball head..... II...37 . 105 Nm [RS] Check tightness of screws at adjustable handlebar • • Relieve load on front wheel...... fit new shims to rear wheel drive or renew bearings.. Freedon from play at piston rod.... Turn steering to left and rock to and fro radially at front end of housing.. Tilt the rear wheel to and fro across the wheel axle. No play should be detected........... III) • Grip rear tyre and try to move it sideways..

....Checking/adjusting throttle synchronisation and CO emission value (Inspection I..........0197 in) 00....5 mm (0.... ..38 • Pre-adjust the wire connecting cable between the throttle stub pipes with the left or right adjusting screw . Adjust wire cable for increased idle speed (choke)..... III. 0..... Adjust the connecting cable to zero play.. II.... Throttle cable play:...039 in) RS130030 • Adjust the wire cable from the throttle twistgrip when the handlebar is on full right lock.. Choke cable play:.. app. IV) RS130040 • RS130020 • • [RT] Remove left side section of fairing..< 1 mm (0.

to the vacuum bores in the throttle stub pipes.... Ride the motorcycle until the engine is warm... BMW No.. Oil temperature:.. RS130050 • • • [RT] Remove the flap at the bottom of the right fairing..... Idle speed: .....39 ......... L Note: Make sure that both throttle valves are closed.. 10 minutes........... or else the basic idle flow setting will have to be reset by the manufacturer. 13 0 800...at least 90 °C (FID: at least 5 bars) • e Caution: The sealed stop screws on the throttles must not be tampered with.............. or alternatively allow it to warm up at a standstill for approx. 00.. 1000 + 150 min-1 20 minutes when the motorcycle is not moving.• Rectify any faults found. carry out fault diagnosis if necessary... e Caution: The engine must not run for more than RS130060 • Set idle speed using recirculating air screws while maintaining synchronous running...... Connect the BMW Synchrotester.... Switch on the Synchrotester 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)...... a See BMW Synchrotester diagnosis instructions. switch to graph display and compare the cylinders..

.. carry out fault diagnosis if necessary......at least 90 °C (FID: at least 5 bars) RT000080 • • Push back the protective rubber cap (1) at the throttle and choke cables.. Choke cable play: .... 13 0 800........ app... to the vacuum bores of the throttles..039 in) • L Note: If the differences between the individual columns are very large (greater than 5 mm)....• With cable junction block 2 • 1 Connect the BMW Synchrotester... a RT000070 • Turn adjusting screws at the left and right throttles to adjust play.. Throttle cable play:...039 in) Throttle cable play:.. app.... BMW No.......... 1 mm (0.. or alternatively allow it to warm up at a standstill for approx.. Ride the motorcycle until the engine is warm.. 10 minutes.. Turn adjusting screw (2) at the throttle and choke cables to adjust play.... e Caution: Engine must not run for more than 20 minutes when motorcycle is not moving.. 1 mm (0. Oil temperature: .....40 Switch on the Synchrotester and select the bar chart with maximum resolution. switch to graph display and compare the cylinders... . See BMW Synchrotester diagnosis instructions... 2 mm (0.......0787 in) 00........ app...

.....5 mm (0... L Note: The height of the bar display must not change when the locknut is tightened......... • Adjust throttle cable play at screws (1).055 RT000080 min-1 L Note: Make sure that both throttle valves are closed. • Repeat this procedure at the right throttle L Note: If play is zero.. Idle speed: .. or else the basic idle flow setting will have to be reset by the manufacturer. 1000 + 150 RS 11. Push the protective rubber cap (2) over the adjusting screw........ Set idle speed using recirculating air screws while maintaining synchronous running.. e Caution: The sealed stop screws on the throttles must not be tampered with. Check the setting by turning the handlebar between the full right and left lock positions. 00.. 0.....41 ...... the throttle butterflies may chatter.. • • • Adjust choke cable to zero play at screw (1). RT000070 • • • Carefully reduce play at the left throttle until the bar display on the Syncrotester changes.. Engine speed must not change during this check.• Push the protective rubber cap (2) back over the adjusting screw. Throttle cable play:.... app. Tighten the locknut..0197 in) 1 1 2 2 RT000140 • • Rectify any faults found... Turn the adjusting screw until the bar display reverts to its original height.

...............2 bar(31.5 (% by vol....16 psi) With pillion passenger + luggage...42 .... Correct if necessary by turning the adjusting screws for the connecting cable... II........5 bar(36....................26 psi) With pillion passenger ..9 bar(42...... RS130070 Tyre pressures: Rider only... front 2... L Note: Make sure that both throttle valves close against their stops when the throttle twistgrip is released. • • Tighten locknuts and check synchronous running again.......... • Check/correct tyre pressures...... 2500 rpm..... rear 2....................... the vacuum columns on the Synchrotester must drop together.1..... 00........ front 2...... rear 2...... take motorcycle for a trial run.........Final inspection with road safety and functional check (Inspection I. front 2...) Check synchronisation of throttles by opening them repeatedly but slowly up to an engine speed of app........9 psi) ...................5 bar (36........... rear 2......... ensure that both throttles return to the limit position when closed............................26 psi) .....7 bar(39.. III........... Idle-speed CO content: . ...06 psi) Roadworthiness check Lights Telltale/warning lights Horn Instruments Special equipment Clutch Gear shift Steering Foot brake and handbrake If necessary......5 bar(36........ IV) Road safety check • Check wheels and tyres.26 psi) ... Seal the vacuum bores. When doing this..............5 • ± 0. • • • • • • • • • • RS130080 • On motorcycles without catalytic converter make sure that the idle-speed CO content of the exhaust gas is in accordance with the nominal value and correct at the idle potentiometer if necessary.

...................................................................................................52 Take off auxiliary frame.......................................................................................................................................................................................................................62 Checking valves for wear .............................66 Removing/dismantling piston ..........................67 .......................59 ...........................................................56 TDC on ignition stroke: .........................................................................................................................................................58 Dismantling/reassembling valve gear holder Removing cylinder head .................................................................................................................................................................................40 Removing engine ....63 Checking valve guide for wear ..............................................................................................................................37 ............................................67 11................................................................................................65 Removing cylinder barrel ..............................................................66 Checking pistons and cylinders Assemble pistons .................................................. ....38 ..................................................39 Cooling oil circuit (with oil thermostat) ............................................................................................................................................................................................... repairing and re-assembling cylinder head .........62 Removing and installing valves ..........................................................57 Assembly specification for timing chain tensioner: ..................................................57 Removing valve gear holder ............................................................63 Remachining valve seat ...................................................................................................................... checking............................................................................................................................................................................................................................55 Locking the engine in the TDC position ..........................................................................................................1 ..........................................................................53 Dismantling engine ........................................................................................................................................................................................................62 Removing valve stem seals ................................................................63 Checking and repairing cylinder head ...........................................................................................................................................................................63 Replacing valve guides ..56 Removing and installing chain tensioner ......................................54 Removing cylinder head cover .............................61 Dismantling.....................................................................................................................11 11 Motor Contents Page Technical Data ....................................................................64 Installing valve and valve stem seal ................................41 Fitting auxiliary frame .............................................................................................................................................................................................. 5 Sectioned drawing of engine Lubricating oil circuit Coolant circuit ...........................

................................................................................................................................69 Renewing radial shaft seal in alternator mount cover .........................................76 Removing and installing oil pick-up basket ...................................................... auxiliary shaft and timing chain tensioning and slide rails ...................................................................................................................................................86 ...........................2 ..................................................................................................................82 Assembling engine block ............................78 easuring radial bearing play ..................................................................................................................................................................................................................................................................................................................................................................77 Removing conrods ........................................87 ....................................................................................................................................................80 ..........................................................................................69 ........................................................................................................................................................................79 Measuring big end bearing play Assembling engine Installing conrod ........................................................................82 Installing timing chain tensioning and slide rails ....71 ....70 Renewing radial shaft seal for rotary breather Removing auxiliary-shaft drive Removing oil pump ..........................................................................................................72 Removing radial shaft seal on crank-shaft with engine installed ....81 ................................85 .........Contents Page Removing/installing conrod ........................................................................................................................................................................................................................................................................83 Installing radial seal on crankshaft Installing clutch housing Installing oil pump 11.................77 Replacing oil level sight glass ...............................................68 Removing and installing alternator cover with engine installed Removing alternator mount cover ..................................................................................................................................77 Measuring main and big end bearing play .................................79 Measuring axial bearing play ............................................82 Installing auxiliary shaft/timing chains .................................................................................................................................................................81 Installing crankshaft ........................................................................78 Install main bearings ..................................................................................73 Dismantling crankcase ................................................................70 ..................................................................................74 Removing crankshaft....................................................72 Oil temperature regulator ..................................................................................77 Checking conrods ........................................................................

.....................................................................................................................88 Installing pistons ..........................................................................................................................................................................................................................................................................................................94 Adjustment specification .....................................................................................................................................................................94 Installing alternator mount cover ...........................................................................................................92 Installing right cylinder head .................................................3 ...........................................................96 Timing the ignition ..................................................................99 11............Contents Page Installing auxiliary shaft drive .....................................................................................................................................................................................................................................................................................97 Installing alternator Installing engin .............89 Installing cylinders ............................96 Installing magnetic gate/belt pulley .......................................93 Installing left cylinder head ....................................................................................................................93 Adjustment specification ...............98 ...................................90 Installing cylinder head ................................................................................................................................91 Adjusting valve clearances ..............

4 .11.

10 (123.16) 3.5 ..898) Stroke mm (in) 70.4717) 9.36) 30 (52...4705.756) Oil pressure warning light comes on below bar (psi) 0.5 (2..11 Technical Data R 1100 RS Engine.3929) Axial play mm (in) 0..0. pints) Cooling oil l (Imp.8) Lubrication system Oil filter Full-flow type Pressure differential needed to open bypass valve bar (psi) 1.04) below 8.98 (0. Location of engine number Crankcase Cylinder bore mm (in) 99. air-cooled with oil-cooled exhaust ports.6.0 (1. general Engine design Four-stroke flat twin.02..5.98 (0.76.95. installed longitudinally.47322. pints) l (Imp. 4 valves per cylinder. pints) l (Imp.12.10...02.41/500) Oil pump Oil pump 2 Duocentric pumps Housing depth mm (in) mm (in) 12.0.5(123..0016. electronic fuel injection.0 (50.11../cylinder head mm (in) 44 (1.0098) Wear limit 11.02) Oil content without filter change with filter change min/max Permissible oil consumption l (Imp.5 (21..6) 0..05 (0.88) l/1000 km Imp. pints) 3.0 (3.75 (6.25) Pressure relief valve opens at bar (psi) 5...0039) mm (in) 0.145..9. looking at ignition system Compression test pressure good normal bar (psi) bar (psi) above 10 (145...3917..87.7...04) 8. torque 66(90)/7250 95/5500 Permissible maximum engine speed -1 min 7900 Permissible continuous engine speed min-1 7600 Idle speed min-1 1000 Direction of rotation +150 Clockwise.5. pints) 36 (63..732) Theoretical volume in circulation at 6000 min-1 Lubricating oil l (Imp..2..50 (0.50 (6.0.47441) 10.0.9.5 (79.0.95.05 (0.25 (0.77) Operating pressure bar (psi) 3.28.04...3945. two high-mounted camshafts....28) poor bar (psi) Intake port dia...1 (0.pint/miles 1.0.5 (2.776) Effective displacement cc Compression ratio Power output 1085 10.7 : 1 kW(bhp)/min-1 Nm/min-1 Max..3957) Height of rotor mm (in) mm (in) 11.0..

.00787) Wear limit mm (in) 0.966.01969) Exhaust mm (in) 1...16551...4..23327) from 1996 mod.00 ± 0.960. year on Inlet mm (in) 4.980 (0.0..06496 ± 0.0118) Valve timing Zero valve clearance.19512.65 ± 0.. Inlet mm (in) 36 (1.5 (0..5. 35 °C) Inlet valve mm (in) 0.30 (0..946 (0.2205) Inlet mm (in) 34 (1.945..23465) Wear limit mm (in) 5..23524) Wear limit mm (in) 5.23386) Exhaust mm (in) 5.1417) Inlet mm (in) 5.2 (0. year on Stem dia.23465.1181 in) valve lift Inlet opens 5° after TDC Inlet closes 33° after BDC Exhaust opens 27° before BDC Exhaust closes 5° before TDC Tolerance ± 3° Valve head dia.4. 3 mm (0.0. engine cold (max.15 (0.0059) Exhaust valve mm (in) 0.19567) Wear limit mm (in) 4.00 ± 0.Technical Data R 1100 RS Valves Included angle between valves ° 41 Valve clearances.2 (0.00787) Wear limit mm (in) 0.19472) Exhaust mm (in) 4.4173) Exhaust mm (in) 31(1.035 (0.01969) Exhaust mm (in) 1.03937) Valve head edge thickness from 1996 mod.23406.03937 ± 0.0.00787) Wear limit mm (in) 0.960 (0.956.19433) Inlet mm (in) 1.00 ± 0.975 (0. exhaust 11.925 (0.01969) mm (in) 0.2 (0.970 (0.5 (0.001378) Inlet Max.5 (0.3386) Exhaust mm (in) 29 (1. year on mm (in) 1.0 (0.03937 ± 0.6 .940 (0.03937 ± 0.0.19606) Wear limit mm (in) 4..5.936 (0. from 1996 mod.. runout of valve head at valve seat Inlet.2 (0.00787) Wear limit mm (in) 1..

26575) Inlet mm (in) 37.00393) Inlet mm (in) 37.34.37..15 (0.1.44161. year on Inlet mm (in) 36..003937) Exhaust mm (in) 30....4 ± 0.09843) Exhaust mm (in) 1.634.34449) Inlet mm (in) 36...32.1 (1..4 ± 0.. year on Inlet mm (in) 33.37.7 .31496 ± 0..1 (1.. (dimension for valve seat machining) from 1996 mod.2 ± 0.00591 ) mm (in) 3.1. dia.0 (0...025 (1.48165.11811 ± 0.3 ± 0.1 ± 0.1.025 (1.00591) Wear limit mm (in) 2.525 (1.2 mm) from 1996 mod.000.19291 ± 0.33859..34386..04331 ± 0..1.43799) Exhaust mm (in) 32.32.500..26083) 11.150 (1.36.25984...617.Technical Data R 1100 RS Valve seat ring Valve seat angle Inlet 45° Exhaust 30° from 1996 mod.5 (0.. year on Seat dia..33957) Seat ring dia.4 ± 0.43701.38583 ± 0.150 (1.. in cylinder head (oversize +0.1 (1.26512.500.47638.00393) Exhaust mm (in) 28.1.633 (1.05512 Wear limit ± 0.1..650 (1..00393) Valve seat extl...36.1..47736) Exhaust mm (in) 34.34.44224) Exhaust mm (in) 32.. (oversize +0..2 mm) from 1996 mod.48228) Exhaust mm (in) 34.1.134..15 (0..1 (1..134.525 (1.11811) Inlet mm (in) 35. year on Inlet 45° Exhaust 45° Valve seat width Inlet mm (in) 1.000.

.01575) Repair stages from 1996 mod. dia.055 (0.15 (0.63984) Rocker shaft dia.032..003937) min.15 (0..49386) Bore in cylinder head mm (in) 12.17 (0.0.00059.025.002205) Wear limit mm (in) 0.056 (0..0.040..000787..070 (0.006693) off-load mm (in) 41. mm (in) 6.044 (0..002126) Wear limit mm (in) 0..016.23681) Radial clearance Inlet mm (in) 0...49343..61811) Wear limit mm (in) 39..0...0. dia.53543) Bore dia.... mm (in) 16.973....500.0.0.561 (0.001575...49283) Overlap mm (in) 0. year on Valve spring Spring length...12.015.8 . dia.030.5. mm (in) 12..0..001969) max. mm (in) 12.12..19732) Radial clearance Inlet mm (in) 0.020..0.0..49409.0.12.... mm (in) 5.49213.0011811.15.501299. mm (in) 12.054 (0.0.0.63055.046 (0..550.006693) Valve guide Intl.001259.012 (0..0.1 (1.19685.62886..05 (0.. mm (in) 0.1 (0..0.0..00591) Exhaust mm (in) 0.501732) Valve guide Intl.002756) Wear limit mm (in) 0.00591) Exhaust mm (in) 0.0..23622...533. dia. Rocker Axial play 11..0.. mm (in) 15..12.. dia..40 (0. mm (in) 0.0.49453) Oversize valve guide Extl.000984.17 (0.0.16.0.0 (1.544 (0.015 (0.001732) Replacement valve guide Extl..0.001811) Wear limit mm (in) 0.744 (0.733.027 (0.984 (0.....Technical Data R 1100 RS Valve guide Valve guide Extl.....002165) Wear limit mm (in) 0.0.62929) Radial clearance mm (in) 0.6.518 (0..

.98264..980 (0......25 (0.94571) Radial clearance mm (in) 0.05 (0..08..00 (0.0.07 (0.15 (0.24.0...21..6318897) Axial play mm (in) 0.074 (0.92.960 (0.040.68 (0.02..0059055) Width of guide bearing mm (in) 15.9433) Bore dia.00175.0.0.0.828346) Camshaft dia.82677) Radial clearance mm (in) 0..9 .02....002913) mm (in) 0..001575..041 (0.0...0027559) Wear limit mm (in) 0.0.020..0070866) Bore dia.16.25..0.95 (0...23.98504...0..006693) Wear limit Bucket-type tappet Wear limit Auxiliary shaft Wear limit 24. in crankcase front/back mm (in) 25.0..0.13 (0.62992..0..62677. dia.26 (0...98346) 11...24.082 (0.18 (0.0. mm (in) 23.0...3811) (valve clearance = 0) Exhaust valve lift mm (in) 9. inlet/exhaust cams 300° Cam spread..000. inlet/exhaust 106°/109° Marking Marking in position 4 Inlet valve lift mm (in) 9..021 (0.000787.040.94488..0098425) Extl. mm (in) 20. in cylinder head mm (in) 24..003228) mm (in) 0.0031496.959.0.21..17 (0.36457) (valve clearance = 0) Camshaft bearing bore dia.0.04 (0.97..15.82559..62795) Width of camshaft bearing mm (in) 16.82756.005118) mm (in) 0.. mm (in) 21.985866) Auxiliary shaft dia.0.Technical Data R 1100 RS Camshaft Opening angle. front/back mm (in) Radial clearance mm (in) 0..947.942795...

.003 (2.36118.000984...018.0.86870.0. mm (in) Green: 54.969 (2.24.2.36232) Yellow: 59. mm (in) 47.89173) Radial clearance mm (in) 0.958 (2.55.013 (2..360197..89039.557047..002519) Wear limit mm (in) 0. mm (in) Green: 59.16461.36295) Main bearing dia..16496) Radial clearance mm (in) 0..940 (0.986339) Axial play mm (in) 0...998.002677) Wear limit mm (in) 0.019 (2..2.009843 in) Grinding stage 0 (grinding stage 1= —0.065.948 (2.020.949. mm (in) Green: 59.88878. mm (in) 60.1.1642..2.....939...053 (0.0.008386) Big end bearing dia.2..47.975....0.25.00787.008. mm (in) Green: 54...Technical Data R 1100 RS Crankshaft Marking of main bearing and crankpin on front crank web no paint mark Grinding stage 0 paint mark Grinding stage 1 -0.050 (1...1 (0.016..991 (1..2.0029527) mm (in) 0..16528......0.36272) Main bearing journal dia.981.22.35980......0031496.59.003937) Main bearing bore dia.0001086.2..87381) Big end bore dia...971..080.97992..3622.974.068 (0.........164567) Yellow: 54.005118) Width of guide bearing mm (in) 24..980 (2.039 (2..964.0..0.36079.013 (2.1...... mm (in) 51.0.55.60.0.0006299.48..016.98504..59.2.88941) Bearing width of crankpin mm (in) 22.000.006417) mm (in) 0.16567..0.557834) Guide bearing dia.2.2....949.075 (0.990 (2.16728) Main bearing journal dia....54.890.001118) Wear limit Grinding stage 0 (grinding stage1= –0.000.163 (0.51..25mm) Connecting rod Wear limit 11... mm (in) 48....007874) Crankpin dia..025.98189) Bearing width of main bearing journal mm (in) 25.10 .60.195 (0.25mm) Guide bearing bore dia.13 (0.13 (0.064 (0...64. mm (in) 64.36055) Radial clearance mm (in) 0.360157) Yellow: 59.54.2.25mm (-0.16689) Yellow: 55.2.2 (0.60..049 (2..

0005905.015..3.0011811) 100 mm from the lower edge mm (in) 0..008 (3.000.0015748) Total wear clearance of piston and cylinder Permitted out-of-roundness of cylinder bore Pistons Piston dia..058 (3.89732.86154.890 (3..86673.130.06 (0.973..) 10 (0.005118. Measuring plane A — and cylinders a see Checking pistons A mm (in) 98.011 (0.899606) B mm (in) 99.12 (0. deviation from parallel of conrod bores at 150 mm spacing mm (in) 0.89626.019685) Small end bearing bore dia.0..3.992.005..989 (3..8968897) Wear limit mm (in) 98.0.8933) B mm (in) 98.3..0..977.04 (0. Wear limit mm (in) 22.0047244) 20 mm from the top edge mm (in) 0.897638.899921) mm (in) 0.897204) Wear limit mm (in) 98..935 (0.025 (0.8935039) Installed clearance mm (in) 0.86358) Conrod end float mm (in) 0.015.86634.0122834) mm (in) 0.89657.0..965..981 (3....866575) Weight classes Weight difference in one class Direction of installation + and — g (oz.12 (0....0....8937) AB mm (in) 98.03 (0.0027559) Cylinders Bore 20 mm (0.Technical Data R 1100 RS Width of big end bearing eye mm (in) 21....35) (complete with pins and rings) Arrow on piston crown pointing to exhaust side Production location towards exhaust side a(see Installing Piston) 11.883.98.11 ....99.3..0.312 (0..0.897638) Wear limit mm (in) 99...3.0023622) Distance between centers Wear limit mm (in) 125 (4.5 (0.92126) Max.21.900 (3..0047244) Piston pin bore dia...0.867126) Radial clearance mm (in) 0.98.011. mm (in) 22.895 (3.000433..896732.22.977 (3.7874 in) from top edge A mm (in) 98.....0018) mm (in) 0..050 (3.99.22.07 (0.98...0.030 (0..0013779) Total wear clearance of piston and cylinder mm (in) 0.897953) Wear limit mm (in) 99.896732) Wear limit mm (in) 98.035 (0.000 (3.

.175.04685) mm (in) 1.0.864567) mm (in) 22.023622) mm (in) 1.094488) mm (in) 0..005.0.0118) mm (in) 0.12 .000 (0..000197.4 (0.86594.8 (0.20 (0.00591) Gap clearance Wear limit Side clearance Wear limit Installed direction of piston rings "Top" marking uppermost Piston pin Piston pin dia.075 (0.04626.0.0.1.86614) mm (in) 21..30..3 (0..0..490 (0.000787.15 (0.043307) mm (in) 0..0...0..3 (0...1 (0....1.002953) mm (in) 0..031496) mm (in) 0.2.8 (0..0006299) mm (in) 0..09744..190 (0..005.011811...0.003937.475.22.1 (0.8665748) mm (in) 0.031496) mm (in) 0..1..003937.175.00591) Gap clearance Wear limit Side clearance Wear limit 2nd groove Micro-taper compression ring Height Wear limit Gap clearance Wear limit Side clearance Wear limit 3rd groove Equal-chamfer ring + tubular spring Height Wear limit mm (in) 2.047244) mm (in) 0.0.09803) mm (in) 2.070 (0.0..0.0..866339..001575..0.00118....60 (0.0118) mm (in) 0.011 (0..15 (0.0.22.040.043307) mm (in) 0.0027559) Bore dia. Wear limit mm (in) 21.030.0.....065 (0.. in piston Radial clearance in piston Wear limit 11.1.04626..002165) mm (in) 0.0.020....00591) mm (in) 1....960 (0..055 (0..002559) mm (in) 0.995..0.0.190 (0.04685) mm (in) 1.0.Technical Data R 1100 RS Piston rings 1st groove Micro-taper compression ring Height Wear limit mm (in) 1.016 (0.15 (0.

28.02.3945.05 (0. pints) l (Imp.145.0.95.0.0016. pints) 36 (63.0 (50..6.5.732) Theoretical vol.9.36) 30 (52..4705...02) Oil content without filter change with filter change min/max Permissible oil consumption l (Imp.95. Location of engine number Crankcase Cylinder bore mm (in) 99...05 (0.0 (3.0039) mm (in) 0.5 (79. torque 66(90)/7250 95/5500 Permissible maximum engine speed -1 min 7900 Permissible continuous engine speed min-1 7600 Idle speed min-1 1000 Direction of rotation +150 Clockwise.3929) Axial play mm (in) 0..3917.6) 0..5(123..0.41/500) Oil pump Oil pump 2 Duocentric pumps Housing depth mm (in) mm (in) 12.16) 3...3957) Height of rotor mm (in) mm (in) 11.12..10. electronic fuel injection..88) l/1000 km Imp.898) Stroke mm (in) 70.9. looking at ignition system Compression test pressure good normal poor bar (psi) bar (psi) bar (psi) Intake port dia.02.0.0 (1.25) Pressure relief valve opens at bar (psi) 5.5 (2.756) Oil pressure warning light comes on below bar (psi) 0. in circulation at 6000 min-1 Lubricating oil l (Imp.47322. pints) Cooling oil l (Imp..50 (0... two high-mounted camshafts.04) 8.Technical Data R 1100 RT Engine.76. air-cooled with oil-cooled exhaust ports.98 (0...7 : 1 kW(bhp)/min-1 Nm/min-1 Max.0098) Wear limit 11. general Engine design Four-stroke flat twin.7..77) Operating pressure bar (psi) 3. installed longitudinally.10(123.25 (0.04) below 8..98 (0.28) mm (in) 44 (1.776) Effective displacement cc Compression ratio Power output 1085 10.5.0.4717) 9.13 .04..5 (21./cylinder head above 10 (145.47441) 10. 4 valves per cylinder. pints) l (Imp.pint/miles 1..0...2.8) Oil filter Full-flow type Lubrication system Pressure differential needed to open bypass valve bar (psi) 1..11...75 (6.0.1 (0.87.5 (2. pints) 3...50 (6..

4. year on Inlet mm (in) 1.970 (0.1417) Inlet mm (in) 5.14 . year on Inlet mm (in) 4..1181 in) valve lif Inlet opens 5° after TDC Inlet closes 33° after BDC Exhaust opens 27° before BDC Exhaust closes 5° before TDC Tolerance ± 3° Valve head dia.23465) Wear limit mm (in) 5..23386) Exhaust mm (in) 5.0.19472) Exhaust mm (in) 4.03937 ± 0..00 ± 0.0059) Exhaust valve mm (in) 0.5 (0.946 (0.2 (0.0 (0.960 (0.16551..035 (0.3386) Exhaust mm (in) 29 (1.00787) Wear limit mm (in) 0.65 ± 0.03937 ± 0.01969) Exhaust mm (in) 1.0.19606) Wear limit mm (in) 4. year on Stem dia.966.23465.975 (0.2 (0.4173) Exhaust mm (in) 31(1...23524) Wear limit mm (in) 5. exhaust 11.960.945.03937 ± 0..19433) Inlet mm (in) 1.00787) Wear limit mm (in) 0...03937) Valve head edge thickness from 1996 mod.925 (0..23327) from 1996 mod..980 (0.0.19567) Wear limit mm (in) 4.23406.5.00787) Wear limit mm (in) 1.2205) Inlet mm (in) 34 (1. Inlet mm (in) 36 (1.956.2 (0.4.06496 ± 0.940 (0.0118) Valve timing At zero valve clearance and 3 mm (0. runout of valve head at valve seat Inlet.01969) mm (in) 0.00787) Wear limit mm (in) 0.30 (0.00 ± 0.01969) Exhaust mm (in) 1.0.001378) Max.5 (0.936 (0.00 ± 0.15 (0.19512... from 1996 mod.2 (0..5 (0.Technical Data R 1100 RT Valves Included angle between valves ° 41 Valve clearance with engine cold (max.. 35 °C) Inlet valve mm (in) 0.5.

11811 ± 0. year on Inlet 45° Exhaust 45° Valve seat width Inlet mm (in) 1..00393) Inlet mm (in) 33.4 ± 0.. (dimension for valve seat machining) from 1996 mod... year on Seat ring dia.32.1..525 (1.37...1.00591 ) Valve seat extl.. year on Inlet mm (in) 36.47638.15 ..43799) Exhaust mm (in) 32....150 (1.38583 ± 0..47736) Exhaust mm (in) 34.1 (1.1.5 (0.09843) Exhaust mm (in) 1. year on Inlet mm (in) 36..25984.00393) Exhaust mm (in) 28.3 ± 0..37.34..650 (1.500.1.1.000.19291 ± 0..525 (1.1.2 mm) from 1996 mod.4 ± 0.34386.134.1 (1.4 ± 0...150 (1.44224) Exhaust mm (in) 32.1 (1.33957) from 1996 mod..33859.32.34449) ± 0...003937) Exhaust mm (in) 30. dia.48165.000.1 ± 0..00591) Wear limit mm (in) 2.36.633 (1.44161.43701.025 (1.26512.48228) Exhaust mm (in) 34.26083) Valve seat ring Valve seat angle Inlet 45° Exhaust 30° from 1996 mod. (oversize +0...1.025 (1.2 ± 0.0 (0.Technical Data R 1100 RT Seat dia..15 (0.04331 ± 0.617.1 (1.134.00393) Inlet mm (in) 37.11811) Inlet mm (in) 35.15 (0...26575) 11.1..500..2 mm) Inlet mm (in) 37..31496 ± 0.. in cylinder head (oversize +0.05512 Wear limit mm (in) 3.36.634.34.

001575.733.500.62886..63055.518 (0. dia.....501299..01575) .001811) Wear limit mm (in) 0.0. mm (in) 6.. Rocker Wear limit Axial play 11....032.550...49386) Bore in cylinder head mm (in) 12..533.12. dia...0 (1.561 (0.030. mm (in) 12.000787..49343..00591) Exhaust mm (in) 0.19685.0.0.00591) Exhaust mm (in) 0.. mm (in) 16..027 (0. mm (in) 5.Technical Data R 1100 RT Valve guide Valve guide Extl.0..49409.49453) Oversize valve guide Extl..973.015.12.012 (0.16.0.0.. mm (in) 15.070 (0.. dia.001969) max..006693) off-load mm (in) 41.. year on Valve spring Spring length. dia..054 (0.000984.002165) Wear limit mm (in) 0.23622.62929) Radial clearance mm (in) 0.49283) Overlap mm (in) 0....0..0.544 (0.0.1 (1..53543) Bore dia.15 (0..044 (0.0..002205) Wear limit mm (in) 0.0.61811) Wear limit mm (in) 39.0.0.17 (0.0011811.6.0...025.12..001732) Replacement valve guide Extl.744 (0...0. mm (in) 12.05 (0...63984) Rocker shaft dia.003937) min.49213.0.046 (0. mm (in) 0....16 mm (in) 0.5.00059.15 (0..015 (0.19732) Radial clearance Inlet mm (in) 0.17 (0.0.002126) Repair stages from 1996 mod..501732) Valve guide Intl.001259. dia.055 (0.020.15.006693) Valve guide Intl..0.0.0..23681) Radial clearance Inlet mm (in) 0..0.984 (0... mm (in) 0.016.. mm (in) 12...1 (0.056 (0.12.40 (0..002756) Wear limit mm (in) 0...0.040.

02.000787.62795) Width of camshaft bearing mm (in) 16..0.24.960 Bore dia.25.23.08.0031496.005118) mm (in) 0.68 (0...0059055) Width of guide bearing mm (in) 15. inlet/exhaust cams 300° Cam spread.0.0.04 (0.....05 (0.040..041 (0.828346) Camshaft dia.21...82559.3811) (valve clearance = 0) Exhaust valve lift mm (in) 9...98346) 11..0.0.07 (0. front/back mm (in) Radial clearance mm (in) 0..0098425) Extl....15...0....94571) Radial clearance mm (in) 0. inlet/exhaust 106°/109° Marking Marking in position 4 Inlet valve lift mm (in) 9.98504.0.18 (0.26 (0.020.25 (0..0.17 (0.040.0...36457) (valve clearance = 0) Camshaft bearing bore dia.000.980 (0.13 (0.985866) Auxiliary shaft dia...0070866) Bore dia.62992.00 (0..21..021 (0.17 .97.94488.0.006693) Wear limit Bucket-type tappet Wear limit Auxiliary shaft Wear limit 24.0027559) Wear limit mm (in) 0..0..82677) Radial clearance mm (in) 0..6318897) Axial play mm (in) 0.62677......82756.082 (0.24...0.074 (0.92. in crankcase front/back mm (in) 25. mm (in) 20.16. in cylinder head mm (in) 24...0.15 (0. dia..98264.002913) mm (in) 0.001575.003228) mm (in) 0.Technical Data R 1100 RT Camshaft Opening angle. mm (in) 23..0..00175.0.947.02. mm (in) 21.959..0..95 (0.

mm (in) Green: 54.164567) Yellow: 54...948 (2.964.88941) Bearing width of crankpin mm (in) 22.....2..0.018.980 (2...98189) Bearing width of main bearing journal mm (in) 25..0.....0031496...25mm (-0.24...60.59.16496) Radial clearance mm (in) 0.0...080.97992.008.053 (0...068 (0...971...16461....064 (0.60. mm (in) 64. mm (in) Green: 54.13 (0.25.163 (0.009843)) Grinding stage 0 (grinding stg.. 1=—0..049 (2..2 (0.1 (0..065..55.2.0...2.25mm) Guide bearing bore dia.18 ..005118) Width of guide bearing mm (in) 24.360157) Yellow: 59.0.2.2.981.998...2..47.16689) Yellow: 55..2.1..Technical Data R 1100 RT Crankshaft Marking of main bearing and crankpin on front crank web no paint mark Grinding stage 0 paint mark Grinding stage 1 (-0.....25mm) 11..54..54...002519) Wear limit mm (in) 0.88878.86870. mm (in) Green: 59.557047..000. mm (in) Green: 59.003 (2.969 (2.986339) Axial play mm (in) 0.0.360197.974.36118.2.006417) mm (in) 0.59.36055) Radial clearance mm (in) 0..002677) Wear limit mm (in) 0...991 (1.. 1 = –0.2.36079.22......98504.3622...940 (0..36232) Yellow: 59..16567.55.64.0.2.020.939...60.195 (0.36295) Main bearing dia.013 (2.0.949.87381) Wear limit Grinding stage 0 (grinding stg.35980.890. mm (in) 47.0001086. mm (in) 60.990 (2.1642..016.003937) Main bearing bore dia.0006299.16728) Main bearing journal dia.019 (2.039 (2.958 (2..16528.007874) Crankpin dia.975.36272) Main bearing journal dia.557834) Guide bearing dia.949.

992. Wear limit mm (in) 22..22.025.973.12 (0.019685) Small end bearing bore dia.86154.0.89626.0027559) Cylinders Bore 20mm (0.12 (0.015.8933) B mm (in) 98..989 (3...3.3.8937) AB mm (in) 98.5 (0.030 (0.965.Technical Data R 1100 RT Connecting rod Big end bore dia.075 (0.896732) Wear limit mm (in) 98..0.0023622) Distance between centers Wear limit mm (in) 125 (4.000433..035 (0.058 (3.000..0122834) Wear limit mm (in) 0..0015748) Total wear clearance of piston and cylinder Permitted out-of-roundness of cylinder bore Pistons Piston dia Measuring plane A — and cylinders a see Checking pistons A mm (in) 98.0. mm (in) 51.312 (0..981 (3.000984..98.899921) mm (in) 0.89732....0018) mm (in) 0.. mm (in) 48.050 (1..8968897) Wear limit mm (in) 98.013 (2.897638.015.0..7874 in) from top edge A mm (in) 98...867126) Radial clearance mm (in) 0.92126) Max.3...04 (0.016..0..900 (3..000 (3.13 (0...86673..0..89657..0.3.050 (3.895 (3.0013779) Total wear clearance of piston and cylinder mm (in) 0....000. deviation from parallel of conrod bores at 150 mm spacing mm (in) 0.0005905.025 (0.001118) Width of big end bearing eye mm (in) 21...0047244) 11.98.03 (0.98..8935039) Installed clearance mm (in) 0.99.1.99.0029527) mm (in) 0..005118..0.19 ..977 (3.011.890 (3.899606) B mm (in) 99..008 (3.51.0.130....07 (0..897638) Wear limit mm (in) 99.48...008386) Big end bearing dia.2.00787..0047244) 20 mm from the top edge mm (in) 0.0011811) 100 mm from the lower edge mm (in) 0..896732.3.897204) Wear limit mm (in) 98.977..897953) Wear limit mm (in) 99..21...86358) Conrod end float mm (in) 0..89173) Radial clearance mm (in) 0.89039.883..0.935 (0.06 (0.

.00591) Gap clearance Wear limit Side clearance Wear limit Installed direction of piston rings "Top" marking uppermost Piston pin Piston pin dia...043307) mm (in) 0...0...175.175...0.3 (0.1.04626.04626.35) (complete with pins and rings) Arrow on piston crown pointing to exhaust side Production locating towards exhaust side a (see Installing piston) Piston rings 1st groove Micro-taper compression ring Height Wear limit mm (in) 1...0.040..0.0.094488) mm (in) 0.0.8 (0.000197..0..995.1.0.86614) mm (in) 21.475.8665748) mm (in) 0.15 (0.09744.86594.490 (0.22.0.002165) mm (in) 0..20 ..002559) mm (in) 0.055 (0.0.020..1 (0.960 (0.....043307) mm (in) 0.070 (0..0118) mm (in) 0.Technical Data Piston pin bore dia.866339.60 (0.. in piston Radial clearance in piston Wear limit 11.023622) mm (in) 1.0118) mm (in) 0.20 (0.00591) Gap clearance Wear limit Side clearance Wear limit 2nd groove Micro-taper compression ring Height Wear limit Gap clearance Wear limit Side clearance Wear limit 3rd groove Equal-chamfer ring + tubular spring Height Wear limit mm (in) 2.001575. R 1100 RT mm (in) Weight classes Weight difference in one class 22.00118.....0..0..04685) mm (in) 1.190 (0.1.30.15 (0.011 (0.8 (0.3 (0.86634.0...030....000787..016 (0.866575) + and — g (oz.003937...0.005.4 (0...1 (0.031496) mm (in) 0... Wear limit mm (in) 21.000 (0..0.22....011811.075 (0.011 (0.002953) mm (in) 0..0.0.031496) mm (in) 0.0027559) Bore dia.0..04685) mm (in) 1..005.2..0.09803) mm (in) 2....22.065 (0.003937.864567) mm (in) 22.00591) mm (in) 1.0006299) mm (in) 0.15 (0.1.190 (0.0.047244) mm (in) 0.005.) Direction of installation 10 (0.

25) Pressure relief valve opens at bar (psi) 5..10 (123...6) l (Imp.3 : 1 1000 +150 Clockwise.05 (0.0.77) Operating pressure bar (psi) 3.50 (0..0.87.5..6) 0..41/500) 1.28.2.50 (6..756) Oil pressure warning light comes on below bar (psi) 0.5(123.10.3945.0.4705.28.0.47322...5 (2.95.50 (0..88) l/1000 km 1.25) 0. installed longitudinally.87..1 (0.445) 99..98 (0...5..36) Cooling oil l (Imp.25 (0..3957) 12. torque Permissible maximum engine speed -1 min 8100 Permissible continuous engine speed min-1 7800 Idle speed min-1 1000 Direction of rotation poor 97/5250 7600 +150 bar (psi) above 10 (145.0098) Wear limit 11...0.. pints) 30 (52.145..28) Intake port dia.7.3 : 1 kW(bhp)/min-1 52(70)/7000 Nm/min-1 77/5500 Max. two high-mounted camshafts..0.1 (0.47322./cylinder head 59(80)/6750 7800 Clockwise. pints) 0.9.756) 1.75 (6.0098) 0..9.98 mm (in) (0.8) 36 (63.5 (21.6.95.5.04.28) mm (in) 44 (1. pints) 3.0..02) Oil content without filter change with filter change min/max Permissible oil consumption l (Imp..04) bar (psi) below 8..02.4717) 9.5 (21...4705.02) 3.04) bar (psi) 8.9.pint/miles (1.0 (3.7. 4 valves per cylinder..50 (6...5 (3.88) 3.76.....11. air-cooled with oil-cooled exhaust ports.776) Effective displacement cc 848 Compression ratio Power output 1085 10..98 (0..0 (1.3929) Axial play mm (in) 0.10..3929) 11.11.41/500) Oil pumpe Oil pump 2 Duocentric pumps 2 Duocentric pumps Housing depth mm (in) 12..0. looking at ignition system above 10 (145.0 (50.2.36) 30 (52..25 (0.6.898) Stroke mm (in) 70.02.0.732) 44 (1.3945.0...0 Imp.. electronic fuel injection.5 (79.05 (0..5 (2.04.75 (6.77) 5.76..9. looking at ignition system Compression test pressure good normal 10.5(123.5 (79.02..12.47441) 10.0. pints) 3.3917.16) l (Imp..05 (0. pints) 36 (63..0039) 0..8) Lubrication system Oil filter Full-flow type Full-flow type Pressure differential needed to open bypass valve bar (psi) 1. Location of engine number Crankcase Cylinder bore mm (in) 87.776) 70. general Engine design Four-stroke flat twin...5 (2.21 ..12.04) below 8.5 (2.145..Technical Data R 850 GS R 1100 GS Engine.0...4717) 9.0039) mm (in) 0.05 mm (in) (0.47441) 10.3917.0016. in circulation at 6000 min-1 Lubricating oil l (Imp.95.10 (123.16) 3.95..0....02..0 (50....3957) Height of rotor mm (in) 11.0.732) Theoretical vol.0016.98 (0..5.04) 8..

.19606) 5.4.925 (0..00787) Wear limit mm (in) 0.0118) Valve timing At zero valve clearance and 3 mm (0.16551.23465) Wear limit mm (in) 4..1181 in) valve li Inlet opens 1° before TDC 1° before TDC Inlet closes 29° after BDC 29° after BDC Exhaust opens 28° before BDC 28° before BDC Exhaust closes 16° before TDC 16° before TDC Tolerance ± 3° Tolerance ± 3° Valve head dia..035 (0.2 (0.23524) Wear limit mm (in) 4.00787) 1.. Inlet mm (in) 32 (1.0059) 0. year on Max.16551.19472) 5.0.2 (0.19567) 5.5 (0.0.03937 ± 0. 35 °C) Inlet valve mm (in) 0. year on Inlet mm (in) 34 (1. from 1996 mod.15 (0.19512..936 (0..0..0118) 0.2 (0..2 (0.30 (0.19606) Stem dia.25984) 36 (1.0.....0.19433) Inlet mm (in) 1.956.00787) Wear limit mm (in) 0.945.. exhaust 11.2205) from 1996 mod.23465.00787 ) 1.5.2 mm (in) 1.960.01969) 1.01969) 0.03937) Inlet mm (in) 1.06299) 31(1..03937 ± 0.5 (0.946 (0.03937 ± 0.23406..1417) Inlet mm (in) 4.966.03937 ± 0.3386) Exhaust mm (in) 29 (1.Technical Data R 850 GS R 1100 GS Valves Included angle between valves ° 41 41 Valve clearance with engine cold (max.65 ± 0.00 ± 0.19512.4.00787) Wear limit mm (in) 0.966.06496 ± 0.035 (0.19567) Wear limit mm (in) 4.001378) 0.5 (0.936 (0.4.5 (0.5 (0.2 (0. runout of valve head at valve seat Inlet.19433) 5.30 (0.5.970 (0.00 (0.956.00 ± 0..19472) Exhaust mm (in) 4.00787) Wear limit mm (in) 0.01969) Exhaust mm (in) 1.980 (0.01969) Valve head edge thickness Exhaust ± 0.01969) mm (in) 0.980 (0.975 (0.23386) Exhaust mm (in) 4.. year on Wear limit mm (in) 4..001378) from 1996 mod..0 (0.960 (0.940 (0.4173) Exhaust mm (in) 27 (1.23327) Inlet mm (in) 4..970 (0.946 (0.0059) Exhaust valve mm (in) 0..22 .03937 ± 0.15 (0.4.00 ± 0.0.00 ± 0.

500..43799) Exhaust mm (in) 32. year on Inlet 45° Exhaust 45° Valve seat width Inlet mm (in) 1...30.000.00393) Inlet mm (in) 34.47736) Exhaust mm (in) 30.003937) 35....003937) 30.00591 ) mm (in) 3.26512....00591) Wear limit mm (in) 2.1. year on Inlet mm (in) 36.23 .634..1 ± 0.25984.150 (1.150 (1.1.134.1.34449) Inlet mm (in) 36.1 (1.4 ± 0..1811.09843) Exhaust mm (in) 1.617.34.1.15 (0.003937) Exhaust mm (in) 26.025 (1.11811) 3.05512 Wear limit ± 0.09843) 2.1.525 (1.2 mm) from 1996 mod..31496 ± 0.34386....05512 ± 0.11811 ± 0..134.2 mm) from 1996 mod.36254.1 (1.00591) 1.186378.. in cylinder head (oversize +0.00393) Exhaust mm (in) 28.36.03937 ± 0..18701) 34.4 ± 0..36.1.48228) Exhaust mm (in) 30..1 (1...2 ± 0.1.025 (1.525 (1. (oversize +0.Technical Data R 850 GS R 1100 GS Inlet 45° 45° Exhaust 45° 30° Valve seat ring Valve seat angle from 1996 mod. (dimension for valve seat machining) from 1996 mod..5 (0.15 (0.634.33957) Seat ring dia..500.....134.44224) Exhaust mm (in) 32.32..47638.15 (0.18209) 34.650 (1..525 (1.359252) 37.32.0 (0..48165.1..500.0 (0..1 (1..37.38583 ± 0.04331 ± 0.30.000.1.633 (1.150 (1.1 (1.025 (1.43701.1 (1.19291 ± 0..3 ± 0.34.1..36417) 37.44161.11811) Inlet mm (in) 31..1..04331 ± 0. dia.1.1 ± 0.37.00591 ) 1..358268.23622 ± 0..000.4 ± 0. year on Seat dia.26575) Inlet mm (in) 34..34..4 ± 0...4 ± 0...5 (0.00393) Valve seat extl.33859... year on Inlet mm (in) 33.650 (1.15 (0.4 ± 0.26083) 11.34.

006693) Valve guide Intl.561 (0.....12.00591) Exhaust mm (in) 0.032.744 (0.012 (0..0..001969) 0.003937) min.49386) 12.49283) 12.0.002756) Wear limit mm (in) 0.0.00059.002165) Wear limit mm (in) 0.518 (0...63055.030...044 (0.054 (0.0 (1..544 (0.15. mm (in) 12.561 (0.49409.05 (0.. mm (in) 12..0..500.49386) Bore in cylinder head mm (in) 12..001969) max.1 (0.973.002126) Wear limit mm (in) 0...12.0.001259..001811) 0...0.046 (0..744 (0.733.0...025.001732) 0. dia.054 (0.0.. mm (in) 0.0.1 (1.19732) Radial clearance Inlet mm (in) 0.23681) Radial clearance Inlet mm (in) 0.0....19685..533.070 mm (in) 0.17 (0.550..000787..0.0.01575) 0..62886..0.... dia mm (in) 5.19685.020.49343.016..40 (0.5.001811) Wear limit mm (in) 0.0.000984.533.0.53543) Bore dia.550.16.015..0.0 (1.015 (0.501732) Valve guide Intl..61811) Wear limit mm (in) 39... mm (in) 16.05 (0..19732) 6....49409.12..62929) Radial clearance mm (in) 0.00591) 0.1 (0... mm (in) 12.1 (1..056 (0.01575) Repair stages from 1996 mod...5.001575.0.006693) 0.0. dia. year on Valve spring Spring length.17 (0..0.49453) Oversize valve guide Extl. dia mm (in) 5.16.. dia..15..12.24 .0.0....0. mm (in) 0.001259...0.040...984 (0.0..63984) 16...Technical Data R 850 GS R 1100 GS Valve guide Valve guide Extl.501732) 12.001732) Replacement valve guide Extl.0.0...973.53543) 39.044 (0.0.002205) Wear limit mm (in) 0.. mm (in) 15.0.056 (0..15 (0..6.0..020..23622.12.0..0.49213.0.016.0.0.17 (0.0.030.61811) 41.62886.544 (0..501299.055 (0.046 (0.015.500....012 (0. Rocker Axial play 11.49343.006693) off-load mm (in) 41..003937) 0...40 (0..027 (0.49453) 12...501299..15 (0.15 (0..63984) Rocker shaft dia.000787.12....0..12.63055...0011811.002126) 0.518 (0.49283) Overlap mm (in) 0..62929) 15...027 (0.12.49213.....00059.0011811.733.002205) (0.032.0...0..984 (0.00591) Exhaust 0.

.005118) Wear limit mm (in) 0... mm (in) 23.000787.0031496..15 (0....02...0..98504.97..04 (0. in crankcase front/back Wear limit 11.0.82677) Radial clearance mm (in) 0.92.24.02.985866) 25....82756..0.82756.074 (0.21..17 (0.0.0..17 (0.0098425) 0.62795) 15..0.947.021 (0.0...0031496.020.0098425) Extl.62992.. dia.24...947....985866) Auxiliary shaft dia.828346) 21....003228) mm (in) 0....25.24.001575.3811) (valve clearance = 0) 9. front/back 24.24...18 (0.94571) 24..25 .0059055) Width of guide bearing mm (in) 15.0..16.25 (0..95 (0.04 (0.0..0...23...959.040.0..0..0.23.00175...82677) 20.....55 (0.021 (0.97.62992.828346) Camshaft dia.25.002913) mm (in) 0. mm (in) 21..98504.040.92..041 (0...041 (0.0.. inlet/exhaust 103°/112° 103°/112° Marking in position 1 Marking in position 1 Inlet valve lift mm (in) 9.13 0..21.33661) (valve clearance = 0) 8.00 (0...0027559) (0.55 (0..05 (0.6318897) 16.0.000787.0.960 23.0..15.0...68 (0.95 (0..001575.980 (0.00 (0.000.040....0070866) mm (in) 25..05 (0....25 (0..980 mm (in) (0.18 (0.82559...960 Bore dia.15.08.020..62795) Width of camshaft bearing mm (in) 16.02.0059055) 0...0.0.00175.94488.0..07 0..33661) (valve clearance = 0) Camshaft bearing bore dia.0027559) Camshaft Marking Wear limit mm (in) 0.0.006693) 0.15 (0.0.Technical Data R 850 GS R 1100 GS Opening angle.0.3811) (valve clearance = 0) Exhaust valve lift mm (in) 8.98346) 24.98264.13 (0.0.959.08.98346) Radial clearance mm (in) 0.6318897) Axial play mm (in) 0.0.074 (0..082 (0. in cylinder head mm (in) 24.94488.006693) Bucket-type tappet Wear limit Auxiliary shaft Bore dia.62677. inlet/exhaust cams 300°/284° 300°/284° Cam spread.21..16.002913) 0...0070866) 0.0.0.02.62677.000.82559..003228) 0.94571) Radial clearance mm (in) 0.040..082 (0.07 (0....21.0.... mm (in) 20.68 (0.98264..0.0.0.005118) (0..

003937) Main bearing bore dia.557047.013 Yellow: 59...008.24.36055) Radial clearance mm (in) 0.049 (2. mm (in) Green: 59.006417) (0..25mm) 11.020....064 (0.16689) Wear limit Yellow: 55..22.2.59..2.986339) 25..0...36079..0...360197..59.59.360157) Green: 59..0..0. mm (in) 60.020.019 (2.0.557834) 64..54..964..25..890.64.2.000..958 Yellow: 59.164567) Green: 54...13 (0...2 (0.1 (0..36232) Crankshaft Marking of main bearing and crankpin on front crank web Grinding stage 0 (grinding stg.97992..60..0...25.998. mm (in) Green: 54.998..939..958 (2.86870.55.0..2..87381) Grinding stage 0 (grinding stg....60.... mm (in) 47. 1=—0.59.54.. 1 = –0.25mm) Yellow: 59....47.940 (0.47.981.195 (0.26 .164567) Yellow: 54.980 (2..981.60.60...35980.36272) (2.2....948 (2....1642.065.005118) Width of guide bearing mm (in) 24..16689) Green: 54.98189) 24. mm (in) 64.3622..2.88878..991 (1.0..016.068 (0.0..195 (0...013 (2.974..0..0001086..16496) (2.0031496.974.969 (2..0.0.2.54.003 (2.36079..005118) 0.557047.002519) 0.. mm (in) Green: 59..2....949.002519) mm (in) 0.35980.000..97992.0001086...064 (0.16528.2.0.0.55...949.2.007874) Crankpin dia.16461..Technical Data R 850 GS R 1100 GS no paint mark Grinding stage 0 Grinding stage 0 paint mark Grinding stage1 (-0..969 (2.86870.019 (2....16567.939...049 Yellow: 55.3622..557834) Guide bearing dia....039 (2....16496) Radial clearance mm (in) 0.080.2 (0..16461..986339) Axial play mm (in) 0.971..36118...87381) 22.009843)) Grinding stage 1 (-0..949.975..16728) (2.0031496..975..2.940 (0.971.88878.25mm (-0...964....068 (0.008.003 (2.25mm (-0. mm (in) Green: 54..16567..36232) Green: 59.16728) Main bearing journal dia.018.16528..64.88941) Bearing width of crankpin mm (in) 22.2....55.009843)) Guide bearing bore dia.36118.36295) Main bearing dia.36272) Main bearing journal dia..948 (2.22.2.007874) 0.98504..54..006417) Wear limit Wear limit mm (in) 0.053 (0.163 (0..24..13 (0.990 Yellow: 54.1 (0.98504.065...002677) mm (in) 0..003937) 0.36295) 60..36055) (2.018...080.039 (2..0006299..890.2.2.990 (2.1....0..55.002677) 0..991 (1.60..1642.949.163 0.88941) 47....016.60.0006299.980 (2.2.1.0.2.053 (0.98189) Bearing width of main bearing journal mm (in) 25...360197..2..2.360157) Yellow: 59.2.

44055) 98.899921) mm (in) 0.011.977 (3.058 (3.0047244) 20 mm from the top edge mm (in) 0.0. deviation from parallel of conrod bores at 150 mm spacing mm (in) 0..0027559) Cylinders Bore 20 mm (0..86673.7874 in) from top edge A mm (in) 87..0.06 (0.0015748) Total wear clearance of piston and cylinder Permitted out-of-roundness of cylinder bore Pistons Piston dia.89626.008386) 51.897638) Wear limit mm (in) 87.89657..005118...550 (3..025.050 (1..86358) 21.04 (0.558 (3..008 (3.883.87.3.0013779) (0.019685) Small end bearing bore dia..87..000984.0018) mm (in) 0.3.890 (3.485 (3...444134) 98.8933) B mm (in) 87.98.895 (3...3...8937) AB mm (in) 87...1.477.001118) 0.030 (0..011..Technical Data R 850 GS R 1100 GS Connecting rod Big end bore dia...900 (3.87.44382.44489.0011811) 100 mm from the lower edge mm (in) 0.92126) 125 (4.001118) Width of big end bearing eye mm (in) 21..0.44685) 99.015.0047244) 0.465.3.015..075 (0.075 0.0.0013779) Total wear clearance of piston and cylinder mm (in) 0.896732) Wear limit mm (in) 87.015.2.07 (0.0.0.0.508 (3.21.....0.13 (0...12 (0.87..130.447165) 99.0122834) (0.000433. mm (in) 48.7874 in) from top edge 20 mm (0.015..1.443976.3.013 (2...050 (3.4452) 99..12 (0.....500 (3.0.867126) 22...0011811) 0.981 (3...04 (0.87.....312 (0...00787..0..443977) 98.897953) Wear limit mm (in) 87..473.000433...98...019685) 0.030 (0.395 (3..0047244) 0.0.992.013 (2.99. (Measuring plane A — and cylinders) a see Checking pistons A mm (in) 87.06 (0..4435...44429) 98.025 (0.0122834) mm (in) 0.0005905.27 .86154.0..00787..86358) Conrod end float mm (in) 0.48..89732.0015748) 0.0.935 (0.3.89039.13 (0.0.12 (0.016..0. Wear limit mm (in) 22...897204) Wear limit mm (in) 87.03 (0.977.89173) Radial clearance mm (in) 0..98.016.000 (3.492.0018) 0...000.000984..0027559) 0.. mm (in) 51.500.0047244) 11.0023622) 0..312 0...000.22...8968897) Wear limit mm (in) 87...89173) 48.400 (3.51..8935039) Installed clearance mm (in) 0.965..025.481 (3.000.896732..92126) Max..3.050 (1.03 (0...5 (0.0023622) Distance between centers Wear limit mm (in) 125 (4.2.3...989 (3.897638.899606) B mm (in) 87.44075) 98.86154..0005905.444567.973..44489) 98..5 (0.0..935 (0.130.07 (0.0...48.025 (0.477 (3.005118..0.0029527) Wear limit mm (in) 0.12 (0..3..008386) Big end bearing dia.3.0..22.390 (3.867126) Radial clearance mm (in) 0.4409448) 98..0.21..51.89039...99.035 (0.035 0..883.0029527) (0...86673.

.0.023622) mm (in) 1...2.86594.190 (0..0.170.86634.002165) mm (in) 0.0.0027559) .09744.0.005.04626..475.1.0027559) 0.60 (0.0. in piston 22.00118.070 (0.Technical Data Piston pin bore dia.070 mm (in) (0.0.....995.22.094488) 0..031496) 0.003937..4 (0..000 (0..00591) Gap clearance Wear limit Side clearance Wear limit 3rd groove Equal-chamfer ring + tubular spring Height 2.020.0.047244) 1.0...04606..0.190 mm (in) (0.0.002559) mm (in) 0.00591) Gap clearance Wear limit Side clearance Wear limit 2nd groove Micro-taper compression ring M-Ring m Ø TOP 4 DZ Height 1.475.005.0....8 (0...047244) Gap clearance Wear limit Side clearance Wear limit Installed direction of piston rings 0..0023622) (0.15 (0..0006299) Wear limit 11..020.0.175.8 (0..070 mm (in) (0.0.0118) mm (in) 1...86614) 21.031496) 0.0.09803) 2.094488) 2...011 (0...000 mm (in) (0.866339.0...0.0.864567) Bore dia.000197.0.3 mm (in) (0..0027559) 0.0.1 (0.960 (0.20 (0..0.8665748) Radial clearance in piston 0.019685) 0.023622) 0.1.04685) Wear limit mm (in) 1.0.0.00591) 0.011811.002953) mm (in) 0.) 10 (0.0.011 mm (in) (0.0118) 0.030.005.09803) Wear limit mm (in) 2..04606...0006299) (0..0.0.00591) 0...1 (0.060 0...22..0.15 (0.030.864567) 21..09744.35) 10 (0.960 (0..22.15 (0.86594.011 (0.04685) Wear limit mm (in) 1.3 (0.0.3 (0.00118.1......055 mm (in) (0.03937) 0.0.22..1 (0.005.22.075 (0.1 (0.043307) 1.15 (0.170..003937.043307) 0.00591) 0.000787.20 (0.001575..2.0...1.. Wear limit 21.005.995..0.....0.070 (0..3..175....040.016 mm (in) (0..065 (0.35) (complete with pins and (complete with pins and rings) rings) Direction of installation Arrow on piston crown Arrow on piston crown pointing to exhaust side pointing to exhaust side Production locating towards exhaust side (see Installing piston) Production locating towards exhaust side a (see Installing piston) Piston rings 1st groove Micro-taper compression ring B-Ring SPT TOP Height 1..0..30..00591) "Top" marking uppermost "Top" marking uppermost Piston pin Piston pin dia..0..016 0..60 mm (in) (0.000787...043307) 1.0027559) 0.15 (0.005.0.04685) 1..0..0..0..0118) mm (in) 0.04685) 1...490 mm (in) (0.011 22....22..8 (0..15 (0.4 (0.866339.011811.0.190 mm (in) (0.5 mm (in) (0.00 (0.30..866575) Weight classes Weight difference in one class + and — R 1100 GS 22.1..000197..1..28 mm (in) 0.0..00118..030. R 850 GS mm (in) 22..1.04626.0118...031496) 0.043307) 0.866575) + and — g (oz.490 (0...003937...0.190 (0...86634.8665748) (0.86614) mm (in) 21...

.0...7.95.445) 99.0.25) 0.9.76. torque Permissible maximum engine speed -1 min 8100 Permissible continuous engine speed min-1 7800 Idle speed min-1 1000 Direction of rotation poor 97/5250 7600 +150 bar (psi) above 10 (145..98 mm (in) (0.6) 0.0039) 0..50 (6. air-cooled with oil-cooled exhaust ports.3945.0016.5 (79.0.pint/miles (1. 4 valves per cylinder. looking at ignition system above 10 (145.0.0...11.2.5.9..47322.87.98 (0.5 (2..5...04) bar (psi) below 8..95.756) Oil pressure warning light comes on below bar (psi) 0.5 (3. pints) 36 (63.3 : 1 1000 +150 Clockwise.36) Cooling oil l (Imp.4705..04) 8.0.3929) 11.0.3917.Technical Data R 850 R R 1100 R Engine...5(123...47441) 10.02..95.756) 1.5 (21.05 (0.29 ..3 : 1 kW(bhp)/min-1 52(70)/7000 Nm/min-1 77/5500 Max..02) 3.12.02...0.28..1 (0....145.77) 5..10 (123..11...5 (21.41/500) 1.0039) mm (in) 0.....3957) 12.88) 3.75 (6.6.8) 36 (63.4717) 9.9.0 (50.3917.50 (6..0 (3..5 (79.898) Stroke mm (in) 70...732) Theoretical volume in circulation at 6000 min-1 Lubricating oil l (Imp.3945.0.87..04...77) Operating pressure bar (psi) 3..776) 70.04) below 8.4705. looking at ignition system Compression test pressure good normal 10.0.. pints) 30 (52.75 (6. pints) 0.0 (1.47322. pints) 3..3957) Height of rotor mm (in) 11.0..28.5 (2.0.7.732) 44 (1.5.776) Effective displacement cc 848 Compression ratio Power output 1085 10..50 (0.25 (0.95.3929) Axial play mm (in) 0.76.05 mm (in) (0.25) Pressure relief valve opens at bar (psi) 5. installed longitudinally.16) l (Imp.0098) 0.1 (0.10..02...50 (0.0098) Wear limit 11.0 Imp..02) Oil content without filter change with filter change min/max Permissible oil consumption l (Imp.4717) 9.28) mm (in) 44 (1.41/500) Oil pump Oil pump 2 Duocentric pumps 2 Duocentric pumps Housing depth mm (in) 12.5 (2. Location of engine number Crankcase Cylinder bore mm (in) 87..98 (0...47441) 10.12...05 (0..0.6) l (Imp.36) 30 (52..0 (50.28) Intake port dia.5..04) bar (psi) 8.25 (0. two high-mounted camshafts..0016.02.98 (0. electronic fuel injection..6. pints) 3.10.145. general Engine design Four-stroke flat twin.5 (2.5(123.8) Lubrication system Oil filter Full-flow type Full-flow type Pressure differential needed to open bypass valve bar (psi) 1.9..2.16) 3../cylinder head 59(80)/6750 7800 Clockwise..0.10 (123.88) l/1000 km 1.04..05 (0.

00 (0.0..2 mm (in) 1.5 (0.946 (0.956.23465) Wear limit mm (in) 4.2 (0.925 (0.0 (0.960 (0.5 (0.2 (0.0..03937 ± 0.00 ± 0.4.2205) from 1996 mod. ab Mj.956.980 (0.01969) mm (in) 0.00787 ) 1.00787) Wear limit mm (in) 0.00787) Wear limit mm (in) 0.936 (0.06299) 31(1.001378) 0.01969) 0.19433) 5.4..00787) Wear limit mm (in) 0.23465.03937 ± 0.00 ± 0.0..0.Technical Data R 850 R R 1100 R Valves Included angle between valves ° 41 41 Valve clearances.0.00787) Wear limit mm (in) 0.1417) Inlet mm (in) 4.975 (0.2 (0.4173) Exhaust mm (in) 27 (1..03937 ± 0.23386) Exhaust mm (in) 4.19433) Inlet mm (in) 1.0. Inlet mm (in) 32 (1. year on Inlet mm (in) 34 (1.946 (0.00 ± 0.16551.19567) 5..940 (0. engine cold (max.945.001378) from 1996 mod.0118) Valve timing At zero valve clearance and 3 mm (0..19606) Stem dia..966.19606) 5.966.4...30 (0.2 (0.01969) Exhaust mm (in) 1.5.3386) Exhaust mm (in) 29 (1. 35 °C) Inlet valve mm (in) 0.. exhaust 11....19512..035 (0.1181 in) valve lift Inlet opens 1° before TDC 1° before TDC Inlet closes 29° after BDC 29° after BDC Exhaust opens 28° before BDC 28° before BDC Exhaust closes 16° before TDC 16° before TDC Toleranz ± 3° Toleranz ± 3° Valve head dia.5 (0.0118) 0.5 (0.03937) Inlet mm (in) 1.25984) 36 (1.00 ± 0.....936 (0.19472) Exhaust mm (in) 4.19472) 5.0059) 0..23524) Wear limit mm (in) 4.15 (0.30 .5.30 (0.2 (0. 96 Wear limit mm (in) 4..23406.19512..03937 ± 0.01969) Valve head edge thickness Exhaust ± 0.15 (0.960.65 ± 0.0059) Exhaust valve mm (in) 0. runout of valve head at valve seat Inlet.00787) 1.06496 ± 0.5 (0.970 (0.4.23327) Inlet mm (in) 4.970 (0.16551.19567) Wear limit mm (in) 4.01969) 1.03937 ± 0.980 (0. year on Max.035 (0.

525 (1.358268.1 (1.15 (0..26512.4 ± 0...1. year on Inlet 45° Exhaust 45° Valve seat width Inlet mm (in) 1.5 (0..4 ± 0..025 (1.186378.38583 ± 0..04331 ± 0.00591) 1..34.32. year on Seat dia...1.634.000..1 (1..00591 ) 1.25984..15 (0.650 (1.1.1.26083) 11..1 (1.5 (0.00393) Inlet mm (in) 34.32.09843) 2.003937) 30.1..4 ± 0..05512 ± 0.617..1. year on Inlet mm (in) 33.15 (0.000.134.1 (1.04331 ± 0...00393) Exhaust mm (in) 28.09843) Exhaust mm (in) 1..003937) 35..1 (1.1 ± 0...1 (1.650 (1.34.4 ± 0...500..003937) Exhaust mm (in) 26.36417) 37.43701.500.05512 Wear limit ± 0.30.Technical Data R 850 R R 1100 R Inlet 45° 45° Exhaust 45° 30° Valve seat ring Valve seat angle from 1996 mod.525 (1.47638.48165.36.48228) Exhaust mm (in) 30.0 (0..18209) 34.23622 ± 0.37..18701) 34..1. (oversize +0.33957) Seat ring dia..34386.150 (1.500.2 ± 0.1.33859..43799) Exhaust mm (in) 32.36.2 mm) from 1996 mod.00393) Valve seat extl..30..525 (1.34.2 mm) from 1996 mod.31 ..31496 ± 0.4 ± 0..44224) Exhaust mm (in) 32.134.150 (1..15 (0..37. dia..11811 ± 0.1...00591 ) mm (in) 3.025 (1.000.34.1..47736) Exhaust mm (in) 30.26575) Inlet mm (in) 34..634.00591) Wear limit mm (in) 2.1 ± 0.44161.11811) 3.025 (1.1811.11811) Inlet mm (in) 31.. in cylinder head (oversize +0..150 (1.0 (0.3 ± 0..1..359252) 37..19291 ± 0. year on Inlet mm (in) 36.36254...4 ± 0.34449) Inlet mm (in) 36.633 (1.134.1. (dimension for valve seat machining) from 1996 mod.03937 ± 0.

561 (0.056 (0.12.032.070 mm (in) 0...0..17 (0.15 (0. year on Valve spring Spring length.1 (1...12.19685..12. dia. Rocker Axial play 11..001575.000984..00591) 0.0011811.0.49453) Oversize valve guide Extl.0.040..0.733..0.001259.0..032...015....733.501299....054 (0.63984) 16..19732) Radial clearancel Inlet mm (in) 0....05 (0.002126) 0. mm (in) 0..49213.020..054 (0.15..0.01575) Repair stages from 1996 mod.00059.002205) Wear limit mm (in) 0.Technical Data R 850 R R 1100 R Valve guide Valve guide Extl..49386) Bore in cylinder head mm (in) 12..0..0.001969) max.0..49386) 12.0.003937) min.61811) Wear limit mm (in) 39.62929) Radial clearance mm (in) 0.17 (0.744 (0..61811) 41..012 (0..0.002126) Wear limit mm (in) 0.12..012 (0.0...0.500.12..1 (0..19732) 6.23681) Radial clearance Inlet mm (in) 0.001969) 0.0.16.0. dia.49453) 12. mm (in) 15..015 (0..49409.015.744 (0.15...0. dia..006693) 0.01575) 0. dia.19685.0.533.49409.025.027 (0.002756) Wear limit mm (in) 0.550..046 (0.046 (0..0.00591) Exhaust 0.1 (1..501732) Valve guide Intl.0.0.15 (0.056 (0. mm (in) 12.550.40 (0.62886. dia..5. mm (in) 0..0...044 (0. mm (in) 16..003937) 0...544 (0.501299..973..49283) 12.001811) 0.001732) 0.00059..0.000787.0.001732) Replacement valve guide Extl..63055.0.12.518 (0..0.62929) 15..973.001259.0.0 (1.53543) 39..05 (0..5..002165) Wear limit mm (in) 0.12....0.016.49283) Overlap mm (in) 0.006693) Valve guide Intl..0.030.533.0.. mm (in) 5.044 (0. mm (in) 12..0.0 (1.32 ...0..984 (0.002205) (0.63055..15 (0..518 (0...40 (0.... mm (in) 5.00591) Exhaust mm (in) 0.001811) Wear limit mm (in) 0.0.006693) off-load mm (in) 41.1 (0..49213.62886.0.020.030..17 (0......984 (0.500.0011811.0..12..53543) Bore dia....561 (0.501732) 12.000787.0..23622.63984) Rocker shaft dia.0.0...16..49343.544 (0. mm (in) 12...49343...6.016..027 (0..055 (0.

02.33 ..0..62677.17 (0......68 (0.82756.0..98504..0..92.98504..0098425) 0..94488.....960 23.16..0031496.020. in crankcase front/back Wear limit 11..13 (0.21..980 (0.62795) Width of camshaft bearing mm (in) 16.24.17 (0.15...13 0.24.003228) mm (in) 0.97..92.24.62992..00 (0..6318897) 16.985866) Auxiliary shaft dia.98346) Radial clearance mm (in) 0.0... front/back 24.0.0098425) Extl......959.18 (0..02.0.21.959..82559.00175..07 (0.021 (0..33661) (valve clearance = 0) Camshaft bearing bore dia.05 (0.0.0.0..18 (0.006693) Bucket-type tappet Wear limit Auxiliary shaft Bore dia.0...00 (0...62677..0.33661) (valve clearance = 0) 8.04 (0.55 (0.94488.020.82677) 20..0..0.021 (0.828346) Camshaft dia.02. inlet/exhaust 103°/112° 103°/112° Marking in position 1 Marking in position 1 Camshaft Marking Inlet valve lift mm (in) 9.08.23.828346) 21.62795) 15.16.040..15 (0..23.0.082 (0.0..0.000787..0... mm (in) 20. in cylinder head mm (in) 24..0059055) 0.95 (0.0..002913) 0.68 (0.0070866) 0..040..15.98264.25.0.005118) Wear limit mm (in) 0..Technical Data R 850 R R 1100 R Opening angle.02.82756..3811) (valve clearance = 0) Exhaust valve lift mm (in) 8..0....0031496.21.94571) 24.947.040..25 (0.05 (0.0..0.082 (0.04 (0..0....3811) (valve clearance = 0) 9.0...947..074 (0.985866) 25.001575.000787.0..0..0.08. inlet/exhaust cams 300°/284° 300°/284° Cam spread.001575. mm (in) 23.980 mm (in) (0..95 (0..00175.. mm (in) 21.041 (0.0059055) Width of guide bearing mm (in) 15.25 (0.98264..82559.000.0070866) mm (in) 25..074 (0.24..6318897) Axial play mm (in) 0.82677) Radial clearance mm (in) 0.002913) mm (in) 0.98346) 24.62992.15 (0.040....94571) Radial clearance mm (in) 0..55 (0.960 Bore dia.21.003228) 0.000.006693) 0.0.0..0027559) Wear limit mm (in) 0.. dia....0.....041 (0.07 0.97..0.0027559) (0..005118) (0.0.25..

.009843)) Guide bearing bore dia..053 (0.35980..97992.36232) Green: 59.002519) mm (in) 0.88941) 47.25. mm (in) 64...000..55.16567.890...60..039 (2.36055) Radial clearance mm (in) 0.974..0..24.0....013 Yellow: 59.360197.005118) 0..36118..557047.002677) mm (in) 0.009843)) Grinding stage 1 (-0.2.98504...0.975.2.88878..2.064 (0.958 (2.2.59..008.0031496...990 Yellow: 54...1 (0..360157) Green: 59.0......016.557834) 64...36079.0..019 (2.971.068 (0.34 .24.974...97992.981..2.013 (2.1.0.975.020.018.59.080.98189) 24.195 (0...0.2..2.36232) Crankshaf Marking of main bearing and crankpin on front crank web Grinding stage 0 (grinding stage 1= —0..54....2..2 (0..969 (2.60.007874) Crankpin dia. mm (in) Green: 59.......940 (0.940 (0...981..60.949.068 (0.195 (0..360157) Yellow: 59.0.3622....039 (2.990 (2..006417) (0.949.35980..0006299...98504.25..003 (2.3622....002677) 0.88941) Bearing width of crankpin mm (in) 22.890.55. mm (in) Green: 54...948 (2..065.0.54.88878.163 (0.Technical Data R 850 R R 1100 R no paint mark Grinding stage 0 Grinding stage 0 paint mark Grinding stage 1 (-0...16496) Radial clearance mm (in) 0.980 (2.64.59..36118.2...019 (2.16728) Main bearing journal dia..25mm (-0.964..16689) Green: 54...0031496...54.55..16461.2.005118) Width of guide bearing mm (in) 24.36272) Main bearing journal dia..002519) 0.998.... mm (in) 60.986339) Axial play mm (in) 0.87381) Grinding stage 0 (grinding stage1= –0.60.86870.980 (2.949.36295) 60..0.2.36272) (2.049 Yellow: 55.16461..98189) Bearing width of main bearing journal mm (in) 25.053 (0.0...25mm (-0.2.0001086.16728) (2.60.003937) 0.998.939.000.55.958 Yellow: 59.2 (0..018..080.2.164567) Yellow: 54.1642..163 0.948 (2.003 (2....2..360197.020.25mm) 11..557834) Guide bearing dia.0..991 (1....0..16567..008.064 (0...16528...971.065.986339) 25.557047..36079..22.16528.25mm) Yellow: 59.2.164567) Green: 54.13 (0.54.2.60..47..59.0001086..0...36055) (2.2.2.003937) Main bearing bore dia......2.36295) Main bearing dia.016.. mm (in) 47.0..1.939.16689) Wear limit Yellow: 55...47.2.007874) 0....64. mm (in) Green: 59.13 (0.0..049 (2...0006299.86870.991 (1.006417) Wear limit Wear limit mm (in) 0.1642.22.969 (2.964. mm (in) Green: 54..16496) (2..1 (0...949..87381) 22...

001118) 0..130...1..050 (1...867126) 22.48.867126) Radial clearance mm (in) 0.973.51.87.8933) B mm (in) 87.99...0047244) 0..0.89173) 48.000984.015.0.92126) 125 (4.897953) Wear limit mm (in) 87.005118.92126) Max..050 (1....86154. Wear limit mm (in) 22..013 (2...312 0..0..0047244) 20 mm from the top edge mm (in) 0...030 (0...44075) 98..000 (3.0023622) 0.. mm (in) 48.000...977 (3....5 (0..86358) Conrod end float mm (in) 0.07 (0..3.025 (0.981 (3..0..477.5 (0..030 (0.025..03 (0.8937) AB mm (in) 87.0005905.0.0027559) Cylinders Bore 20 mm (0..035 0..86673.98.86358) 21...900 (3.899921) mm (in) 0.001118) Width of big end bearing eye mm (in) 21....3..312 (0.89039.965.558 (3...0.0..3.89732..98....447165) 99.8935039) Installed clearance mm (in) 0..44055) 98.3..1.48.44685) 99...44429) 98.2.508 (3.0013779) Total wear clearance of piston and cylinder mm (in) 0...444567.86673.897204) Wear limit mm (in) 87.019685) 0.075 0...035 (0..130.7874 in) from top edge 20 mm (0.87..0.13 (0.935 (0..075 (0.0...000433.0122834) mm (in) 0..00787.0.04 (0..011.477 (3.395 (3.000984.0.0011811) 100 mm from the lower edge mm (in) 0.3.06 (0.44382.000..500.0.0013779) (0.481 (3.492.06 (0.3...21.Technical Data R 850 R R 1100 R Connecting rod Big end bore dia.0.025 (0.896732) Wear limit mm (in) 87..485 (3.87.016..0.44489.473.0.3.4452) 99.015.0029527) (0.883.008386) Big end bearing dia.883.935 (0.07 (0...015.86154.0.89173) Radial clearance mm (in) 0.0005905..897638) Wear limit mm (in) 87.... (Measuring plane A — and cylinders) a see Checking pistons A mm (in) 87.00787.008386) 51.7874 in) from top edge A mm (in) 87.443977) 98..0..89039.992.2..03 (0.98.000433.4435..019685) Small end bearing bore dia.51.21.0..050 (3.008 (3.897638..015.016.0029527) Wear limit mm (in) 0.0015748) 0.35 . deviation from parallel of conrod bores at 150 mm spacing mm (in) 0..3.0027559) 0.0047244) 0.896732.4409448) 98.87.0011811) 0.13 (0.12 (0..013 (2.058 (3.8968897) Wear limit mm (in) 87...0023622) Distance between centers Wear limit mm (in) 125 (4..12 (0..390 (3.12 (0.977.3.550 (3.0018) mm (in) 0....0.443976..87.400 (3.895 (3.89657...0122834) (0.0047244) 11..025.3.0015748) Total wear clearance of piston and cylinder Permitted out-of-roundness of cylinder bore Pistons Piston dia.890 (3.444134) 98.22..989 (3.011.0.465..22..000.99.0018) 0... mm (in) 51....899606) B mm (in) 87.12 (0.44489) 98.04 (0..005118.89626.500 (3.

..00118..0.1.22.190 mm (in) (0.005.0..0.36 mm (in) 0.0.60 (0.001575.0.175...0..030.866575) Weight classes Weight difference in one class + and — R 1100 R 22.475.011811..0.0...15 (0.86634.190 (0.040.011811.04626.170. Wear limit 21.09803) Wear limit mm (in) 2.0.3 (0...023622) mm (in) 1.86634..30.22.003937..070 (0..8 (0.0...00118.0023622) (0.0.0.0.0..00 (0..864567) Bore dia...031496) 0..0.) 10 (0..023622) 0.30.0006299) Wear limit 11..60 mm (in) (0.1......0.0.00591) 0..031496) 0....4 (0..070 mm (in) (0..0.15 (0.04606.020.070 mm (in) (0...1..030.866575) + and — g (oz.15 (0..2..1 (0.04606.8665748) Radial clearance in piston 0....000197.000 mm (in) (0.2.0006299) (0..0..1.0.0027559) ...8 (0.1 (0..1.22.15 (0..09803) 2..0118.170.016 mm (in) (0.070 (0.22.3 mm (in) (0.094488) 0.0..0.005.00591) Gap clearance Wear limit Side clearance Wear limit 2nd groove Micro-taper compression ring M-Ring m Ø TOP 4 DZ Height 1..00591) 0..0.005...002953) mm (in) 0.15 (0.043307) 0..04626.019685) 0...960 (0...3.0.0..0118) mm (in) 1.0...0.1..15 (0..04685) Wear limit mm (in) 1.866339.000197.1 (0.0.011 (0.190 (0..1.0118) mm (in) 0.35) 10 (0.0.047244) 1.0..0027559) 0.030..4 (0..094488) 2.490 mm (in) (0.016 0.864567) 21..490 (0.005.055 mm (in) (0.000787.20 (0.960 (0.0..011 22.995.04685) 1..8665748) (0.0027559) 0.22.86594.995..031496) 0.043307) 1.09744.00591) Gap clearance Wear limit Side clearance Wear limit 3rd groove Equal-chamfer ring + tubular spring Height 2.0.35) (complete with pins and (complete with pins and rings) rings) Direction of installation Arrow on piston crown Arrow on piston crown pointing to exhaust side pointing to exhaust side Production location towards exhaust side (see Installing Piston) Production location towards exhaust side a(see Installing Piston) Piston rings 1st groove Micro-taper compression ring B-Ring SPT TOP Height 1..000787.00591) "Top" marking uppermost "Top" marking uppermost Piston pin Piston pin dia.065 (0.86614) mm (in) 21.Technical Data Piston pin bore dia..003937.04685) 1.0..04685) Wear limit mm (in) 1..86614) 21.0027559) 0.8 (0.043307) 1..0....020.047244) Gap clearance Wear limit Side clearance Wear limit Installed direction of piston rings 0.03937) 0.866339.86594.0.190 mm (in) (0. in piston 22.011 (0..00591) 0....475..0....5 mm (in) (0.00118.075 (0.20 (0.1 (0..060 0...0..0.0.....043307) 0.002165) mm (in) 0.3 (0.... R 850 R mm (in) 22.002559) mm (in) 0.09744..005.0.22.0118) 0.003937..011 mm (in) (0.005.000 (0...175.

37 .Sectioned drawing of engine RS119010 11.

Lubricating oil circuit RS119020 11.38 .

Coolant circuit RS119030 11.39 .

Cooling oil circuit (with oil thermostat) RT119010 11.40 .

GS

00 1 520

RS110520

Removing engine

L Note:

Auxiliary shaft, timing chains, chain tensioner/guide
rails and crankshaft 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.

11.41

RS

1
4
5

13 3 010

3

2

RS160010










Remove dualseat.
[RS/GS/RT] Remove side sections of fairing.
[RS] Detach inner cockpit panel (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.

11.42

RT
6x

C
B
A
13 3 010

3

4

B

A

C

5

6x
RT160060

11.43

3

1

RS

2
GS/R/RT
RS000340


Remove air filter cover (1) and air intake pipe (2).
Remove battery (3).

e Caution:

Disconnect negative terminal first, then positive
terminal.

12 3 520

RS120170


RS130010

Remove Motronic control unit.

11.44

Remove spark plug covers.
Pull off spark plug caps with puller,
BMW No. 12 3 520.

RS340010

[ABS] unit - remove.

L Note:

Retain brake lines with cable straps.

e
Caution:
Always follow the instructions in the repair manua
a See Group 34,Removing and installing
ABS unit.

RS110530


[ABS] Detach brake pipes at gearbox.
[RT] Detach brake master cylinder.

11.45

1
2
3

RS460010


RS110540

[RT] Detach brake master cylinder.
Unfasten right footrest plate


Separate connector/Hall-effect transmitter wire
(1).
Separate connector/oxygen sensor (2).
Pull off plug/NTC-oil temperature (3).

RS610010


RS110510

Detach wire cable junction block.
Remove battery holder

Detach leads from alternator.

RS610020
RS120141

Remove cable strap from cable guide under battery holder.


11.46

[RS/GS/RT] Detach starter-motor cover/pull off
socket cable.
Detach leads on starter motor/remove starter
motor.

4

2
3

1
RS610044




Disconnect oil pressure switch (1).
Separate plug connection for side stand
switch (2).
Separate plug connection for gearbox neutralindicator switch (3).
Detach ground (earth) strap (4).

11.47

2
1

RS110570


[RS] (Version without rotary breather) Detach oil
return line at oil trap (1).
Detach engine breather pipe from engine (2)

11.48

2

1
RT

3

RS110561








Detach oil cooler pipe (1) at left of oil cooler.
[RT] Detach oil cooler line at oil thermostat (3).
Detach right 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.

11.49

e Caution: Detach oxygen sensor cable . 11.50 .do not subject to tension. Remove manifold pipes.GS/R RS180040 • • Remove muffler (silencer).

1 2 5 4 3 1 RS310011 • • • • • Remove covers (1) on leading link pivots. Remove retaining cap (4). Take out bolt (5) at right. Unfasten left screw cap (2). Remove right retaining ring (3). 11.51 .

52 e Caution: Protect tank mount with adhesive tape to prevent scratching. 46 5 630. at rear suspension strut pivot (2). Press front of leading link down (arrow). Detach rear left/right of rear frame. • Center the auxiliary frame over the plane surface of the tank mount. • • • • • Unfasten rear frame screw connection (5) at front left/right. • • • • • Secure front suspension strut at bottom. • Attach auxiliary frame. Insert adapter (6) into the leading link/rear frame mount and secure it to the auxiliary frame. insert threaded bushes (4) fully into the connecting struts/frame and tighten firmly. Unscrew and remove pin (7) securing the frame to the engine. 11. Unfasten lower front suspension strut mount. or pull rear section downwards.4 46 5 630 3 1 2 6 5 7 8 RS111010 Fitting auxiliary frame • Remove the rear wheel. BMW No. • Remove rear suspension strut. Detach left intake pipe at cylinder head and pull downwards. Raise frame assembly at the front. • Install the rear wheel. • Remove upper retaining screw and lower pin in connecting struts (1) between engine and frame. • Hook the auxiliary frame to the front tank mount (3). e Caution: Protect tank mount with adhesive tape to prevent scratching. Withdraw leading link shaft (8) to the left. .

• • Secure front suspension strut at bottom. Press front of leading link downwards or pull rear section downwards. BMW No. Unfasten lower front suspension strut mount. align the front frame bores with the engine bore from the left. Remove gearbox/swinging arm/rear axle/rear wheel together. e Caution: Do not scratch leading link . insert from the left and secure tightly. leads or wire cables. 46 5 623.46 5 623 46 5 620 RS111020 • • Attach frame support. BMW No.53 . Remove auxiliary frame. Do not damage electrical wiring. Apply a light coating of grease to the leading link shaft. • e Caution: Ensure that all components are correctly located. Take off auxiliary frame. insert the pin from the right and screw up tightly. BMW No. 46 5 630. Lower frame assembly at the front. 46 5 620. Using mandrel. • • • • • Detach left intake pipe at cylinder head and pull downwards. to the frame unit. 11.apply adhesive masking tape if necessary. with adapter.

11. using oil filter wrench.11 0 630 RS110010 Dismantling engine • • Attach engine mount. BMW No. 11 4 650. 11 0 630. Transfer engine to assembly frame. BMW No. Remove oil filter. to engine block.54 . 11 4 650 RS110950 • • Drain engine oil.

e Caution: Trap escaping oil. 11. 12 3 510.12 3 510 RS110020 Removing cylinder head cover • • Unscrew and remove spark plugs with spark plug wrench. Remove cylinder head cover. BMW No.55 .

Turn the belt pulley to move the piston to TDC on the ignition stroke. and 2. TDC mark is visible. 11. the inlet and exhaust valves in the cylinder in question are closed. 11 2 650. which is inserted into the clutch housing and the engine block at TDC.003 RS110030 Locking the engine in the TDC position • • Remove front cover. TDC on ignition stroke: 1. BMW No. BMW No. 11 5 640. RS110461 L Note: The engine can be set to top dead center with the TDC pin.11 5 640 TDC RS 11.56 . • 11 2 650 TDC Secure the clutch housing with locking device.

..... 32 Nm 11.. then timing chain tensioner.. • e Caution: Failure to observe this sequence can cause the chain tensioner piston to fall into the left side of the timing chain cavity....... X Tightening torque: Chain tensioner ...RS110060 Removing and installing chain tensioner e Caution: Do not accidentally confuse the chain tensioner pistons..... fit a new gasket....57 ........... Assembly specification for timing chain tensioner: Removal: • Remove timing chain tensioner...... Installation: First install camshaft sprocket...... When installing.. then remove cam-shaft sprocket from camshaft.

L Note: If the camshaft sprocket (1) is not removed after loosening.g. Secure rockers with a rubber band (2).2 M6 x 60 M6 x 30 M6 x 30 M6 x 30 1 RS110070 Removing valve gear holder • • Remove valve gear holder. it must be held firmly and prevented from falling into the engine block (e.58 . RS110051 • • Remove camshaft sprocket cover. L Note: If no work is carried out on the valve gear holder. with a cable strap). remove it together with the cylinder head. Unscrew/press off camshaft sprocket. 11.

e Caution: Do not accidentally confuse rocker shafts and pushrods. 11.59 . Insert a suitable drift into the bore (arrow) of the rocker shaft.M8 x 40 M8 x 30 M8 x 40 RS110080 Dismantling/reassembling valve gear holder • • • Remove bearing cap. and pull the shaft out of the mount by twisting it in both directions. Remove pushrods.

... 15 Nm M 8 screw for camshaft bearing cap ...60 Reposition the bearings until minimum endplay is obtained...00197 in) max..... Remove bucket-type tappets......05 mm (0. e Caution: Do not accidentally confuse the bucket-type tappets.... End float of rocker: min..... 0................ 0.. 15 Nm 11............... ...... RS110100 L Note: Locate pushrods in ball cups on rockers and hold • the rockers together with a rubber band to secure the pushrods in position..........01575 in) X Tightening torque: M 8 screw in rocker shaft bearing cap .... Remove camshaft and bearings (2)......M8 x 65 1 3 2 RS110090 • • • Remove camshaft bearing cap (1)... • Reassemble in the reverse order of work..40 mm (0........ The cutout on the rocker shafts must be aligned with the retaining holes.... e Caution: Note direction of installation (3) for camshaft bearing cap.......

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

Separate valve collet from spring plate by striking the valve head gently. repairing and re-assembling cylinder head Removing and installing valves e Caution: Do not scratch sealing face on cylinder head. scratch-free surface. Remove valve collet sections. to cylinder head.62 .11 1 250 11 5 690 RS110130 Dismantling. 11. checking. the valve stem seal must be renewed. Remove top/bottom spring plates. L Note: If a valve is removed. 11 1 250. 11 5 690. Clamp the valve springs. Place the head on a clean. Relieve tension on valve springs. BMW No. • • • • • • Attach valve spring tensioner. BMW No. valve springs and valves Removing valve stem seals • Pull off valve stem seal with pliers.

Checking and repairing cylinder head Remove combustion residues from combusion chamber. a See Technical Data.. • 11..... a See Technical Data. • Skimming sealing face: . Remachining valve seat B D RS110890 e Caution: Width (B) and diameter (D) must always be maintained when remachining the valve seat. 0..63 ....2 mm (0. • Check sealing face for damage/distortion.. and skim flat if necessary..max. a See Technical Data.Checking valves for wear • Clean combustion residue from valves..00787 in) metal re-moval Checking valve guide for wear Check valve guide bore.. • Check valve dimensions..

0..0.0. Inspect bore in valve guide.236/0.700.7 U6 (12. • Immerse valve guide in liquid grinding paste. Insert valve guides into cylinder head with no delay.0.4934..197 in) dia. 20 °C. • Measure valve guides with micrometer. • Freeze valve guide with dry ice.... 20 °C).015.744 mm) (0.733.044 mm) (0. 11 5 671/673.4928 in).550..015..500.044 mm (0.. • • • – – – Drive out valve guides with 6/5 mm (0..7 H7 mm (12.5017 in) valve guide.00173 in). L Note: Valve guides for repair purposes have an internal diameter of 6.197 in) dia..733. Repair method 1 – ream out the bore (if bore is damaged or not to correct dimensions) • Determine actual diameter of valve guide using micrometer. • Turn down oversize valve guide to nominal dimension.. the temperature must be –40 °C.00 H7 mm/R 850) tolerance range.00173 in). pressing-in arbor BMW No.5013... If valve guide bore is undamaged and dimensions are within correct 12.4921.. • Slowly heat cylinder head to 200 °C in a suitable oven. Attach chilled valve guide to 6/5 mm (0.. Allow cylinder head to cool down to room temperature.4939 in) valve guide. the bore after pressing in the valve guide is in the 6. L Note: Valve guides are installed in the cylinder head with an interference fit of 0.Replacing valve guides • Heat cylinder head slowly and uniformly to 200 °C in a suitable oven.718 mm) (0. • Calculate the nominal diameter of the valve guide: Nominal diameter of valve guide = bore dia.5017 in) valve guide.561 mm (0.64 .4941.. + interference-fit value (0.0..744 mm) (0.5...0.5 U6 (12. 11 5 672/674.50071 in) reamer. Repair method 2 – lathe-turn the valve guide (bore must not be damaged) • Determine actual diameter of bore with internal measuring tool. If valve guide bore is undamaged but slightly larger than the 12.518 mm)(0.12.. it should be opened out.0. extractor pin.236/0.7U6 (12. BMW No.12.00 H7 mm (5...00059. • Use an oversize 12. • Open out bore with Ø12. 11..5 H7 tolerance range: • Use an oversize 12.00059.0... In most cases. e Caution: Immediately before pressing in..12. Allow cylinder head to cool down to room temperature (app.12.0.. • • • • • Place heated cylinder head flat on workbench or a similar surface.12... e Caution: Wear protective gloves when handling heated parts. If the bore is too narrow. from the combustion chamber side. Examine valve guide bore for: wear.01 H7 mm (5..5013.01 H7 mm/R 850)..5 H7 tolerance range: • Use original 12.544 mm) (0.5 H7 tolerance range: • Use replacement valve guide 12.0. app.12. widening taper and correct dimensions in H7 tolerance range (12.4945 in).533. If valve guide bore is damaged or not to correct dimensions in 12...

valve stems.197 in) dia. BMW No. BMW No.197 in) dia.236 in) dia. e Caution: Ensure that valve collets are correctly seated in the valve stem grooves. • • • • Oil the stem when installing the valve. Compress the valve springs with the clamping tool. valve spring and upper spring plate. On 5 mm (0. 11 5 601/602. Fit lower spring plate.236/0. the valve stem seal must be renewed. shrink a short section of shrink-fit tube on the end of the valve stem. Install the valve stem seal with a 6/5 mm (0. Check valves for leakage (blow-by).11 5 600 11 5 690 11 1 960 RS110160 Installing valve and valve stem seal • L Note: • If a valve was removed. 11 5 690 L Note: Insert the taper valve collets using grease (to simplify assembly). assembly sleeve (arrow). on to the valve stem.65 . drift. e Caution: Remove the assembly sleeve and the shrink-fit tube. • • Relieve tension on valve springs. Push the 6 mm (0. 11. 11 1 960. BMW No.

11. Press out piston pin by hand. and remove cylinde e Caution: When removing cylinder. Unscrew and remove cylinder retaining screws. Remove carbonized oil from base of piston/clean the piston. Removing/dismantling piston • • • • • Remove both retaining rings on piston pin. e Caution: Do not accidentally confuse pistons.66 . Remove piston. Carefully remove piston rings with piston ring pliers. ensure that the piston does not strike the engine block. piston pins or piston rings.1 RS110170 Removing cylinder barrel • • Unscrew and remove guide rail bearing screw (1).

.. See Technical Data...787 in) and 100 mm (3. RS110200 RS110180 • a • a Measure cylinder bore with internal probe at 20 mm (0. 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... 6 mm (0... A 2..236 in) See Technical Data.67 .....20 °C............. See Technical Data e Caution: The tubular-spring ring gap must be at 180° to the equal-chamfer ring gap...... Install with the "Top" uppermost.......937 in) from the top in direction of piston pin...Checking pistons and cylinders • Install piston rings in cylinder. RS110190 RS110970 • Measuring plane A :.... 3......... 100 20 Reference temperature for measurements: . a • a Carefully fit piston rings to piston in the following sequence.. and again at a right angle to the first measurement... See Technical Data Assemble pistons R 850 1... 11... Determine piston ring clearance using feeler gauge..

..........lettering facing up 11.. • Screw the big end bolts in by hand......... Installed direction of conrods: ...TDC 11 2 500 11 5 640 RS110210 Removing/installing conrod • • • Turn crankshaft to TDC position....... e Caution: Use big end bolts once only.. 20 Nm Wrench angle ............. 80 ° ... Lock the clutch housing with retaining fixture............68 e Caution: Oil the bearings....... BMW No...... 11 5 640............ BMW No...... 11 2 500....... L Note: Conrods can also be removed/installed with the crankshaft removed................................ • Install conrods. then tighten with an angle-indicating wrench................... e Caution: Do not accidentally confuse conrods or bearing shells........ X Tightening torque: Big end bolts oiled Joint torque...... Remove conrod...

Remove rear leading link mount. Remove rotary breather line (1). Insulate ground (earth) lead.11 5 640 4 2 3 1 RS110230 Removing and installing alternator cover with engine installed • • • Remove dualseat. Remove starter motor. Remove pulley (2). BMW No. • Remove alternator mount cover (4).69 . Lock clutch housing with retaining device. Remove magnetic gate (3). [RS/GS/RT] Remove side fairings. e Caution: Disconnect ground (earth) lead from battery. L Note: If complete alternator mount cover is removed. 11 5 640. • • • [RS/GS/R] Remove starter motor cover. leave magnetic gate (3) installed. Removing alternator mount cover • • • • • Remove alternator. 11. Remove fuel tank.

L Note: Slide new radial shaft seal over taper on slid-ing sleeve.Renewing radial shaft seal in alternator mount cover Renewing radial shaft seal for rotary breather 00 5 550 11 5 650 11 5 680 RS110241 RS110240 • • Carefully lever radial shaft seal out.70 • • • Carefully lever radial shaft seal out. 11 5 680. and drift. BMW No. 11 5 650. 11. . using a screwdriver. BMW No. Drive in a new radial shaft sealing ring with drift and sleeve. using a screwdriver. Carefully pre-form the lip of the radial shaft seal by hand. BMW No. 00 5 550. Drive in the new radial shaft seal (oiled lightly) using handle. pre-shape and pull off.

Remove chain tensioner (2).71 . Remove chain guide rail (4). remove chain sprocket (9). Unscrew and remove cooling oil pipe (1)/swing the pipe forwards. Unscrew and remove chain sprocket retaining bolt (5). If necessary. Remove rotor (6) with chain sprocket (7) and timing chain (8). 11 5 640.11 5 640 2 3 9 8 4 1 7 6 5 RS1100251 Removing auxiliary-shaft drive RS110961 • • • • • • • • • Align markings (arrows) on timing pinion and chain sprocket. Remove chain tensioning rail (3). Lock the clutch housing with retaining device. BMW No. 11.

L Note: Do not dismantle the oil temperature regulator. and dismantle. e Caution: 1 Check installed positions of parts which have already been run together.72 . RT110580 • Expanding element (1).3 1 M6 x 45 2 M6 x 50 M6 x 45 M6 x 50 Removing oil pump • • M6 x 45 RS110410 Oil temperature regulator Remove oil pump cover (1). 11. Remove complete oil pump (2) together with cooling oil pipe (3).

e Caution: Avoid damaging the sealing faces on the housing and the crankshaft. using a screwdriver. 11 5 640.11 5 640 RS210010 Removing radial shaft seal on crankshaft with engine installed • • Lock clutch housing with retaining device. L Note: When dismantling the crankcase.73 . Remove clutch. the radial seal can be taken out. RS110270 • Carefully lever radial shaft seal out. BMW No. 11.

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

Remove screws on left side. Remove upper section of crankcase.75 M6 x 50 M6 x 50 M6 x 35 M6 x 25 M6 x 50 M6 x 50 M6 x 35 M6 x 35 M6 x 35 M6 x 50 M6 x 50 M6 x 50 M6 x 35 M6 x 35 M6 x 35 M6 x 50 M6 x 25 M6 x 25 M6 x 50 M10 x 100 M10 x 100 . 11.RS110260 • • • Turn engine on to its side.

auxiliary shaft and timing chain tensioning and slide rails 11.76 .RS110290 Removing crankshaft.

.... Checking conrods • a RS110300 Check conrod dimensions...77 . e Caution: Sintered-metal conrods must never be straightened – risk of fracture. and is installed undamaged.. X Tightening torque: M6 screw . Coat the sealing face of the new oil level sight glass with engine oil and drive it in with drift.......Removing and installing oil pick-up basket Removing conrods • • Clamp crankshaft in a vise provided with protective jaws... 11... Replacing oil level sight glass • • Pierce the plastic disc with a large screwdriver and lever out the oil level sight glass....9 Nm (0...............354 in) e Caution: Make sure that the O-ring is not omitted.. See Technical Data.. BMW No... Remove conrod e Caution: Do not accidentally confuse the conrods.. 00 5 550.

a See Technical Data.78 . Grinding stages are identified by a paint mark on the front crank web. note colored marks on crankpins and big end bearings. a See Technical Data If the bearing shells have to be replaced. 11. after this it must be rehardened and finished. e Caution: The crankshaft can only be reground in grinding stage 0.RS110310 Measuring main and big end bearing play easuring radial bearing play • Measure main bearing journal with an external micrometer crosswise in two planes. • Enter measured values on record sheet. A and B.

.1 RS110320 Install main bearings • • Insert tensioner rail/slide rail pivot pin (1) for centering purposes.. 00 2 510 RS110910 • • a Screw measuring device BMW No. BMW No..... 00 2 510... • Insert tensioning rail/slide rail pivot pin (1) for centering purposes..... See Technical Data..79 ... in the tapped hole for the alternator mount cover............... 11.. Enter measured values on record sheet and determine main bearing play values.................... Tightening torque/tightening sequence: 1....... • Tighten housing screws...... See Technical Data... Measuring axial bearing play • Place crankshaft in engine block... M10 screw (oiled) .... Move crankshaft forwards and backwards. with dial gauge. 00 2 500... Tighten M8 and M10 housing screws.. and read off play at dial gauge. 45 Nm 2..... M8 screw (oiled) .. 20 Nm • • a 00 2 500 Measure main bearings front/back in the load direction.

..........................................80 Measure big end bearing with internal gauge in thrust direction...... X Tightening torque: Big end bolts oiled Joint torque........... Tighten big end bolt with tightening angle indicator.. 20 Nm Wrench angle .. 11 2 210. Enter measured values on record sheet and determine big end bearing clearances....... 11 2 210 RS110360 • RS110350 • a • • Install bearing shells and assemble conrods. 80° 11.............. BMW No......... .RS110340 Measuring big end bearing play • Measure crankpin with an external micrometer in the thrust direction and offset through 90o ............... See Technical Data.

....... e Caution: Oil the bearings.................81 ...Assembling engine Installing conrod 11 2 210 RS110370 • • Clamp crankshaft in a vise provided with protective jaws...........lettering facing up X Tightening torque: Big end bolts (oiled) Joint torque..... 20 Nm Wrench angle ........................ Screw big end bolts (oiled) in by hand and tighten with tightening angle indicator. BMW No......................................................... Do not accidentally confuse conrods or bearing shells........ Installed direction of conrods: .. Always use new big end bolts... 80° 11.................. 11 2 210......

..u 2 1 RS110291 Installing crankshaft e Caution: Oil the bearings.... X Tightening torqu: Chain guide rail pivot pin ... using a new sea.82 Installing auxiliary shaft/timing chains e Caution: Timing chains (2) must mesh fully with auxiliary shaft sprockets........ Installing timing chain tensioning and slide rails • • Seal pivot pin for tensioning rail/slide rail at clutch side (arrow) with 3-Bond 1209.......... Insert pivot screw (1) into chain tensioner rail. . 18 Nm 11.......

grease-free sealing faces (arrow) with 3-Bond 1209. Secure the timing chain with rubber band (1) to the timing chain tensioning and slide rail. 11.1 M6x50 M6x50 M6x35 M6x25 M6x50 M6x35 M6x35 M6x35 M6x50 M6x50 M6x50 M6x50 M6x35 M6x35 M6x35 M6x25 M6x25 M6x50 M6x50 M10x100 M10x100 u RS110920 Assembling engine block • • Coat clean.83 .

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

and drift with sliding sleeve. 00 0 500.1 2 3 4 11 5 660 RS110400 Installing radial seal on crankshaft • • • • Pre-form the lip of the radial shaft seal carefuilly by hand (1). BMW No. Drive radial shaft seal in with handle.85 . 11. 11 5 660 (4). Place radial seal over sliding sleeve (2)/remove sliding sleeve (3). Oil the radial shaft seal at the sealing/contact surface. BMW No.

.. BMW No...... Insert all screws by hand and tighten down...................... Lock clutch housing with retaining device................ • • • Install clutch housing with mark (1) aligned with crankshaft mark (2).... 11 5 640..... 32° 11....86 .. X Tightening torque: Clutch housing to crankshaft (screw threads oiled) ................. 40 Nm Additional wrench angle .2 1 11 5 640 RS210011 Installing clutch housing e Caution: Always use new bolts for housing and cover.

e Caution: Note: different lengths of screw.............1 2 3 M6 x 45 4 5 6 7 M6 x 50 M6 x 45 M6 x 50 M6 x 45 RS110411 Installing oil pump e Caution: Oil the sliding-contact faces......... Install oil pump housing with cooling oil pipe (2)................. outer rotor (5) and inner rotor (6) in cooling oil pump.................. • • Install Woodruff key (4)........ Screw housing cover (7) on to oil pump... • • Install outer rotor (1) of oil pump in pump houssing................. 30 Nm 11. 9 Nm Pressure relief valve ............ X Tightening torque: M 6 screw ....... 35 Nm Oil pressure switch.... e Caution: O-ring (3) must be in good condition......87 .........................

................. 10 Nm • Install drive-shaft chain with chainwheel (2) and rotor (3)....... 11 5 640.. Install chain tensioner housing (6) with piston and spring...............11 5 640 6 5 1 4 7 2 3 RS110250 Installing auxiliary shaft drive • • e Caution: Set crankshaft mark against mark on auxiliary shaft......... Tighten down cooling oil line (7).......................... X Tightening torque: Retaining screw at chainwheel ......... X Tightening torque: M 6 screw ............................. 70 Nm • • • Install/secure chain guide rail (4)............. 25 Nm ............... a • • Lock clutch housing with retaining device............... 25 Nm Banjo screw for cooling oil line with oil vent valve ......... 10 Nm Banjo screw for cooling oil line.......... 9 Nm 11............... Use a new sealing ring...................... X Tightening torque: M 6 screw ............... BMW No....... Install chain sprocket (1)..88 X Tightening torque: M 6 screw ...... e Caution: Perform the work in accordance with the adjustment specification See Installing cylinder head.... Install/secure chain tensioner rail (5)........

B.. B 11........ AB (for either A or B cylinder).. Markings: ... Production locating point X = install on exhaust side.... and on cylinder A..89 ... Do not accidentally confuse pistons or piston pins Piston size identificatio On piston crown A. Oil the sliding-contact faces........ + or — a See Technical Data e Caution: Always install pistons and cylinders in pairs.... e Caution: Ensure that retaining rings are properly seated on piston pin..... Install piston ring gap offset by 120° in each case.X RS110430 Installing pistons • • Turn joint in oil scraper ring (arrow) so that it faces upwards... Always use pistons of the same weight class in any one engine...................

.....................90 ....... which must be clean and free from grease... Tighten cylinder down firmly.. compress the piston rings.... Install chain sprocket.......11 2 900 u 1 RS110420 Installing cylinders • • • • • • • Apply 3-Bond 1209 to the cylinder base sealing face.. Fit new seal to pivot pin for chain guide rail (1).......... 20 Nm 2. Tightening torque/tightening sequence: 1.. M 6 screw ........... Using piston ring clamp strap............... M 8 screw .................. 9 Nm 3... 11 2 900/11 2 905...... 18 Nm 11... BMW No............ Oil the cylinder wall. Pivot screw for chain guide rail..... Install the cylinder and at the same time pass the timing chain and the tensioning and guide rail through the timing case cavity.

....... Tighten one nut to initial value ........ Tighten camshaft chain sprocket.. Unfasten one nut 2.................... 40 Nm 3..... 90° 1..................... Unfasten/retighten M10 screw ..................... Install valve gear support (2)....2Tighten all nuts to correct angle ... X Tightening torque: Chain tensioner .......... Tighten camshaft chain sprocket. Install chain tensioner...... 20 Nm 3. Tighten cylinder head nuts (oiled) crosswise 1................ 90° 2........... Lock clutch housing with retaining device........ • X Tightening torque: Camshaft sprocket retaining screw ........ M 10 screw ............................ Tighten nut to wrench angle ......... 65 Nm • • Tightening torque/tightening sequence: 1........ e Caution: Install collar (arrow) of cylinder head nut towards cylinder head.............. M 6 screw .............. 600 miles) Tighten cylinder head nuts crosswise 1.... Check that marks on camshaft sprockets are in accordance with adjustment specification..............................2 M6 x 60 M6 x 30 M6 x 30 1 M6 x 30 RS110930 Installing cylinder head • • • • • • Install cylinder head gasket. 20 Nm 1... 180° 4......91 . Tighten cylinder head down.. BMW No. • • • Insert the left-side camshaft sprocket with pin into the camshaft and set the left cylinder to TDC on the ignition stroke........ Fit camshaft chain sprocket in accordance with adjustment specification.... Fit cylinder head/insert correctly positioned camshaft chain sprocket (1) and timing chain into chain cavity...3Tighten all nuts to correct angle .. 11 5 640.. 32 Nm X Tightening torque: take up slack after 1000 km (app...1Tighten all nuts....... 40 Nm 11... 9 Nm Fit camshaft chain sprocket in accordance with adjustment specification........

........ 35 °C): Inlet ...... 0..... it must be possible to insert the feeler gauge between valve stem and rocker with only slight resistance to movement.0118 in) X Tightening torque: Locknut ....... 11................30 mm (0...................15 mm (0........ Measure valve clearance with feeler gauge......0059 in) Exhaust ................... 0.........92 ............... 8 Nm • Check valve clearance again................. Correct valve clearance with adjusting screw and lock into position.....RS110980 Adjusting valve clearances • • • Set piston to TDC on the ignition stroke. Valve clearances with engine cold (max....

RS110961 Right cylinder = at TDC on ignition stroke: marks (arrows) on chainwheel/auxiliary shaft and chain sprocket/crankshaft are aligned. at hole in clutch housing and en-gine block. 11 2 650. always start with the right cylinder.Installing right cylinder head Adjustment specification e Caution: When assembling.93 . 11. • Check setting again with timing chain tensioner installed. Mark (R or arrow) and tip of tooth on right camshaft sprocket is precisely aligned with mark X on timing gear carrier. X RS110150 • Locate ignition-stroke TDC with insert pin. Right cylinder = at TDC on ignition stroke Locating pin (arrow) on right camshaft sprocket points downwards. BMW No.

always begin with the right cylinder. 11. X RS110511 • Locate ignition-stroke TDC with insert pin. Mark (R or arrow) and tip of tooth at left camshaft sprocket is aligned precisely with mark X on timing gear carrier. 11 2 650. BMW No. RS110963 Left cylinder = at TDC on ignition stroke: Marks (arrows) on chainwheel/auxiliary shaft and chain sprocket/crankshaft point downwards. • Check setting again with timing chain tensioner installed.Installing left cylinder head Adjustment specification e Caution: When installing. Left cylinder = at TDC on ignition stroke: Locating pin (arrow) on left camshaft sprocket points upwards.94 . at hole in clutch housing and in engine block.

..95 .... reduce end play to a minimum by repositioning the bearings.................................05 mm (0... 9 Nm 11......... RS110940 • Install cylinder head cover......RS110050 • Install the end cover with an O-ring which is in good condition... e Caution: Ensure that gaskets are properly seated....................0157 in) RS110440 • Tighten air intake stub pipe....... ..... 0...................... 0.............................. 9 Nm and sealing face must be free from oil and grease X Tightening torque: Cover screw...... Rocker end float: min..................40 mm (0. 8 Nm RS110100 • If necessary..00197 in) max.. Gaskets X Tightening torque: M 6 screw ........................................ X Tightening torque: M 6 screw .......................................

.. BMW No. X Tightening torque: Vent line to alternator mount cover M 8 screw ........... which must be clean and free from grease...............96 ........................ rotor location at Hall-effect gate) at the groove/ crankshaft (5)....... BMW No.... e Caution: Install the belt pulley lock (4) (from model year 1995 on........ Apply 3-Bond 1209 to the sealing face (arrow)...... 11 5 680........... X Tightening torque: M 8 screw .......... 9 Nm • • Install Hall-effect trigger plate (1)............................. X Tightening torque: Retaining screw for belt pulley . 50 Nm • Install rotary breather pipe (3) with new sealing rings.. [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)....... 25 Nm 11............ 11 5 640........ 20 Nm Banjo screw .........................5 11 5 640 11 5 680 1 2 3 6 u 4 RS110450 Installing alternator mount cover Installing magnetic gate/belt pulley • • • • • Place sliding sleeve............................. Install the Poly-V belt pulley... 20 Nm M 6 screw ...... on crankshaft. Lock clutch housing with retaining device...................... Install alternator mount cover..

11. 12 3 650. BMW No. and adapter lead. 12 3 650 12 3 652 RS110460 • • • • Connect ignition tester. BMW No. BMW No. Tighten plate on Hall-effect trigger. to magnetic gate. 11 2 650.97 .11 2 650 TDC RS110461 Timing the ignition • Prevent clutch housing from moving with TDC insert pin. Turn the Hall-effect gate plate until the telltale lamp just goes out. 12 3 652. Remove the TDC insert pin.

.....3 2 1 RS110480 Installing alternator • Install alternator.98 RS110490 • Install front cover... • Tighten adjusting screw (2) with a torque wrench............... tension..... Adjusting procedure for Poly-V belt: Installation procedure for Poly-V belt: • Place Poly-V belt in position... (using no tools)...... ... X Tightening torque: Pre-tension Poly-V belt with adjusting screw.. Poly-V belt tensioning procedure: • Screw up hex nut (1) at adjusting screw (2) lightly by hand.... 20 Nm 11... turn the engine over once and relieve belt tension. fully tighten retaining nut (3).... slacken adjusting screw and tighten screws fully... 8 Nm Alternatorto alternator support cover.....

BMW No.....Installing engin • Work in reverse order to that stated for removal............................... 32 Nm 12 3 510 RS000010 • Install spark plugs with spark plug wrench....... 12 3 510..........99 ........ 11 Nm Oil drain plug... BMW No....... 11 4 650........ Insert and tighten oil drain plug with a new seal.......... X Tightening torque: Oil filter (sealing face lightly oiled) ........... X Tightening torque: Spark plug... 11 4 650 RS110950 • • Install oil filter with oil filter wrench....... 20 Nm 11................

..............................................................................................................................................................................................................................15 12..............................................................................................12 Dismantling/reassembling starter motor Renewing carbon brushes Checking starter motor Checking starter relay ................7 Removing and installing alternator ...............................................................................................................................................................................13 Removing and installing magnetic gate Timing the ignition ...................11 .......13 .......................1 ....................................................................................................7 .................13 ..............................................................................................................................................................................................12 12 Engine electrics Contents Page Technical Data ..... 3 Removing and installing coil and ignition lead Checking ignition coil resistance ........................13 ...................14 ..............................8 Adjusting procedure for Poly-V belt: ......................................10 Checking alternator ...............................................................................................................11 Checking armature for short to ground (earth) Removing and installing starter motor .......................................................................................................................................................................................................................9 Dismantling/reassembling alternator .....................................................................................

2 .12.

0394) metric M 14 x 1.12 Technical Data R 1100 RS Starter motor Type Permanent-magnet motor with planetary gear drivee Gear ratio Planetary gears 5. operating speed min 700/14 A 50 A 18 -1 20 000 Aluminum Poly-V belt pulley Extl.25 Thread Ignition Ignition system Motronic (mapped characteristic control) Ignition trigger Two magnetic gates (Hall-effect transmitters) driven from crankshaft Ignition timing °KW 0° — + 43° before TDC Static ignition timing °KW Adjustment at TDC Motronic converts TDC value into 6° before TDC Ignition coil Twin-spark coil Resistance: Primary. dia.5 : 1 Power rating kW 1. measured at tips of teeth Wear dimension mm (in) Spark plug Bosch FR 6 DDC Electrode gap mm (in) 0.5 Maximum output rating W/V Maximum current at engine speed 4000 min-1 Nominal current at engine speed 1000 min-1 Max.3 . Ω ~0.1 Alternator Type Three-phase alternating-current generator with integrated all-electronic voltage regulator Drive Poly-V belt Gear ratios 1 : 1.5 kΩ ~13 between terminals 15 and 1 Secondary..8 (0.0315) Wear limit mm (in) 1.0 (0. between terminals 4a and 4b 12.

0 (0..5 : 1 Power rating kW 1.8 (0.0315) Wear limit mm (in) 1. operating speed 700/14 A 50 A 18 min-1 20 000 Aluminum Poly-V belt pulley Extl.25 Thread Ignition Ignition system Motronic (mapped characteristic control) Ignition trigger Two magnetic gates (Hall-effect transmitters) driven from crankshaft Ignition timing °KW 0° — + 43° before TDC Static ignition timing °KW Adjustment at TDC Motronic converts TDC value into 6° before TDC Ignition coil Twin-spark coil Resistance: Primary.5 kΩ ~13 between terminals 15 and 1 Secondary. dia.1 Alternator Type Three-phase alternating-current generator with integrated all-electronic voltage regulator Drive Poly-V belt Gear ratios 1 : 1. measured at tips of teeth Wear dimension mm (in) Spark plug Bosch FR 6 DDC Electrode gap mm (in) 0.4 .Technical Data R 1100 RT Starter motor Type Permanent-magnet motor with planetary gear drive Gear ratio Planetary gears 5.0394) metric M 14 x 1. between terminals 4a and 4b 12. Ω ~0.5 Maximum output rating Maximum current at engine speed W/V 4000 min-1 Nominal current at engine speed 1000 min-1 Max.

0315) 0. dia.Technical Data R 850 GS R 1100 GS Starter motor Type Permanent-magnet motor with planetary gear drive Gear ratio Planetary gears 5.5 1 : 1.5 Maximum output rating Maximum current at engine speed W/V 700/14 4000 min-1 Nominal current at engine speed 1000 min-1 Max. operating speed 700/14 A 50 50 A 18 18 min-1 20 000 20 000 Aluminum Poly-V belt pulley Extl.25 M 14 x 1.5 (2.8 (0.5 : 1 Power rating kW 1.0 (0.0394) metric M 14 x 1.0394) 1. Ω ~0. kΩ ~13 ~13 between terminals 4a and 4b 12.0315) Wear limit mm (in) 1.1 Alternator Type Three-phase alternating-current generator with integrated all-electronic voltage regulator Drive Poly-V belt Poly-V belt Gear ratios 1 : 1.0 (0. measured at tips of teeth Wear dimension mm (in) 55.5 ~0.185) Spark plug Bosch FR 6 DDC FR 6 DDC Electrode gap mm (in) 0.5 : 1 1.1 Planetary gears 5..5 between terminals 15 and 1 Secondary.25 Thread Ignition Ignition system Motronic (mapped characteristic control) Ignition trigger Two magnetic gates (Hall-effect transmitters) driven from crankshaft Ignition timing °KW 0° — + 43° before TDC 0° — + 43° before TDC Static ignition timing °KW Adjustment at TDC Adjustment at TDC Motronic converts TDC value to 6° before TDC Ignition coil Twin-spark coil Resistance: Primary.5 .8 (0.

0315) 0.0 (0. dia.6 kΩ ~13 ~13 .1 Alternator Type Three-phase alternating-current generator with integrated all-electronic voltage regulator Drive Poly-V belt Poly-V belt Gear ratios 1 : 1.8 (0. Ω ~0.185) Spark plug Bosch FR 6 DDC FR 6 DDC Electrode gap mm (in) 0.5 between terminals 15 and 1 Secondary.25 M 14 x 1..25 Thread Ignition Ignition system Motronic (mapped characteristic control) Ignition trigger Two magnetic gates (Hall-effect transmitters) driven from crankshaft Ignition timing °KW 0° — + 43° before TDC 0° — + 43° before TDC Static ignition timing °KW Adjustment at TDC Adjustment at TDC Motronic converts TDC value to 6° before TDC Ignition coil Twin-spark coil Resistance: Primary.5 Maximum output rating W/V 700/14 Maximum current at engine speed 4000 min-1 -1 Nominal current at engine speed 1000 min Max.0315) Wear limit mm (in) 1.5 : 1 1. measured at tips of teeth Wear dimension mm (in) 55.8 (0.0 (0.0394) metric M 14 x 1.Technical Data R 850 R R 1100 R Starter motor Type Permanent-magnet motor with planetary gear drive Gear ratio Planetary gears 5.5 (2.185) 55.5 1 : 1.5 ~0.1 Planetary gears 5.0394) 1. operating speed 700/14 A 50 50 A 18 18 min-1 20 000 20 000 Aluminum Poly-V belt pulley Extl.5 (2. between terminals 4a and 4b 12.5 : 1 Power rating kW 1.

[RS] Remove inner fairing panel at fuel tank. Seal. Separate plug connector (2). • • • • • • • • [GS/R] Detach Motronic control unit and pull it out upwards. Remove plug cap (5) with puller. Remove ignition coil (1). BMW No. Install in the reverse order of work. 12 3 520. Pull off ignition lead (3). Remove ignition lead. [RS/GS/RT] Remove side sections of fairing. e Caution: Switch off ignition. Remove vent pipes. 12. Checking ignition coil resistance a See Technical Data. Disconnect ground (earth) cable at battery and insulate it. [R] Remove tank cover. loosen and pull off fuel feed and return line with hose clip BMW No. 13 0 010. Remove fuel tank.1 3 2 3 5 12 3 520 4 5 RS120010 Removing and installing coil and ignition lead • • • • • • • • • Remove dualseat.7 . Separate plug for fuel pump. Unscrew fuel tank mount. Remove spark plug cover (4).

[ABS] . Take off Poly-V belt pulley and belt.8 • • • • • • • • • Remove Motronic control unit. • Install in the reverse order of work. Detach connecting leads (1) from alternator. Seal. Insulate ground (earth) lead.1 2 2 2 3 RS120020 Removing and installing alternator • • Remove dualseat. e Caution: Do not scratch other parts. . [R] Remove fuel tank cover. Separate plug for fuel pump. Remove strut (3) from frame at left. 13 0 010. BMW No. Unscrew fuel tank mount. Remove alternator. loosen and pull off fuel feed and return line with hose clip. Remove front cover from engine. 12. disconnect if necessary.detach pressure modulator. Unscrew alternator mount (2). Loosen Poly-V belt pulley at alternator. • • • • • • • [RS] Remove inner fairing panel at fuel tank. [RS/GS/RT] Remove side sections of fairing. e Caution: Disconnect ground (earth) lead from battery. Remove fuel tank. Remove vent pipes.

............. fully tighten retaining nut (3)......... 15 Belt pulley at alternator..... X Tightening torque: Poly-V belt preload . Screw up hex nut (1) at adjusting screw (4) lightly by hand (using no tools) • Tighten adjusting screw (4) using torque wrench.3 4 2 1 RS110480 Adjusting procedure for Poly-V belt: Poly-V belt installation procedure: • Place the Poly-V belt in position........ turn the engine over once.................. 2.. slacken off adjusting screw and tighten down screws........... 20 Positive lead to alternator .................. tension it......................... 8 Alternatorto alternator support cover..9 ... • • L Note: Siehe auch Serviceinformation 12 020 95 (700)... then relieve belt tension Poly-V belt tensioning procedure: Loosen alternator mount (1... 3).. 50 Nm Nm Nm Nm 12...

. Install in the reverse order of work............. X Tightening torque: Belt pulley at alternator. Remove the Poly-V belt pulley........1 2 3 RS120050 Dismantling/reassembling alternator • • • • • Take out the cover retaining screws (1)..... 50 Nm 12... Remove voltage regulator (3). Release clips (2) and remove the cover.10 .......

...11 . 3 Ω Checking armature for short to ground (earth) OL RS120060 • Measure resistance between sliprings and armature Measured result:.... RS120070 • Using BMW Diagnosis tester.............. Ω-key is to be pressed until the digital display reads 0.. BMW No....... calibrate to zero with the BMW diagnosis tester: Connect the positive (yellow) and negative (green) leads together.......Checking alternator L Note: Before each Ω measurement..... 61 1 510.......OL = open line 12......00 Ω... Nominal resistance:. measure resistance between the sliprings....................

......... X Tightening torque: Starter motor to engine .. 7 Nm Positive lead to starter motor......... Take out retaining screws (4) and remove the starter motor..........12 .. Detach connecting lead (3).... 20 Nm Starter motor cover to gearbox housing ..... [RS/RT] Remove left side section of fairing.. Install in the reverse order of work................... • • • • [RS/GS/R] Remove cover (1) for starter motor and pull off wire (2) for power socket. 10 Nm 12...... e Caution: Disconnect ground (earth) lead from battery.3 4 2 4 1 RS120140 Removing and installing starter motor • • Remove dualseat... Insulate ground (earth) lead..

Remove release lever (6) and spring (7) from solenoid switch (8)...... Remove retaining screws (2)......0 Ω • Connect positive supply to terminal 85 and negative supply to terminal 86.... Remove holder (12) for carbon brushes... 80..... Install in the reverse order of work...app... insert the Ω meter between terminals 30 and 87...... Remove retaining ring (9) and take starter motor gear assembly (10) off shaft.............. Ω value: .... Slide short lead (15) on to threaded pin................... Ω value .... Press the Ω key until the digital display reads 0..... (-) to terminal 86b............ Remove flange (3)... calibrate to zero with the BMW diagnosis tester: Connect the positive (yellow) and negative (green) leads.11 V Checking starter relay L Note: Before each Ω measurement.. Then: Connect (+) to terminal 85..13 .............150 A • Voltmeter connected to (+) and (-) on starter motor Starter is in good working order at: .... Coat the steep-angle thread and the engaging ring with Bosch PZ 2 V 3 silicone grease................ • After calibation.......... Renewing carbon brushes • • • • • • • • Detach lead (1)..................app...... 0 Ω 12. Remove solenoid switch (4) after taking out the retaining screws (5)..... Remove cover (11)......... Lift up retaining springs (13) and remove carbon brushes (14). The relay must be energized..4 7 8 1 5 6 14 9 2 11 10 13 3 15 12 RS120080 Dismantling/reassembling starter motor Checking starter motor • • • • • • • • • Detach lead (1)........... Engine temperature > 20 °C Ammeter in positive lead to starter motor..... Starter is in good working order at: ......... Install carbon brushes with retaining plate............... Attach lead (1)................ 10........00 Ω.... Install cover (11).....................

Remove front cover from engine. Slacken off alternator mount (2) and relieve tension on Poly-V belt. 11 5 640. Remove starter motor.14 Separate plug connection (1) for magnetic trigger. [RS] Remove inner fairing panel at fuel tank. [RS/GS/R] Remove starter motor cover/pull off power socket lead. RS180050 e Caution: Disconnect ground (earth) lead from battery. [R] Remove tank cover. Lock clutch housing with retaining device. [RS/GS/RT] Remove side sections of fairing. . Unscrew fuel tank mount and carefully move the tank to the rear. place foam rubber mat or similar item under tank.2 1 5 6 4 3 5 RS120090 Removing and installing magnetic gate • • • • • Remove dualseat. Insulate the ground (earth) lead! • • • • • • 12. 1 e Caution: Do not scratch paint. BMW No.

. 50 Nm Lock the clutch housing with the TDC insert pin... RS110461 • X Tightening torque: Pre-tension of Poly–V belt ...... Tighten plate on Hall-effect trigger. Remove OT (TDC) insert pin.. and adapter lead.... 11 2 650 TDC e Caution: Install lock (7) for belt pulley [from 1995 model year on location at Hall-effect gate rotor] in groove/crankshaft (7). 12 3 652.. [from 1995 model year on] Secure rotor (6) of Hall-effect gate with Loctite instant adhesive or similar to the Poly-V belt. to Hall-effect trigger plate.......... 8 Nm Alternatorto alternator mount cover . BMW No. Turn plate until telltale lamp just goes out... BMW No........ Install in reverse order of work..... Carefully dismantle magnetic trigger lead.. 20 Nm Belt pulley to crankshaft .......... 12 3 650. Einbaulage der Magnetschranke für Wiedereinbau kennzeichnen. Remove pulley (4)....• • Remove rotary breather pipe (3).... Slacken off plate of Hall-effect trigger.... BMW No.. 12...... 11 2 650.... • • • Remove magnetic trigger (5)....15 . Timing the ignition L Note: Ggf. 12 3 650 12 3 652 RS110460 • • • • • Connect ignition tester..... Tension Poly-V belt according to installation procedure...

...............................................................................................................................13 13 Fuel preparation and control Contents Page Technical Data ............... 3 Removing and installing air cleaner ..9 Removing and installing Motronic control unit .......................................8 .................1 ....9 13............7 Removing and installing throttle stub pipe Removing and installing injectors .......................................................................................................................................................................................................................

2 .13.

dia. Throttle angle in rest position Air cleaner mm (in) ° 45 (1. 95 octane (RON) Mixture preparation Motronic MA 2.2 Throttle stub pipe intl.13 Technical Data R 1100 RS Fuel grade Super (premium).3 . unleaded.772) 10 Circular paper element 13.

unleaded.Technical Data R 1100 RT Fuel grade Super (premium).2 Throttle stub pipe intl. 95 octane (RON) Mixture preparation Motronic MA 2. dia. Throttle angle in rest position Air cleaner 13.4 mm (in) ° 45 (1.772) 10 Circular paper element .

unleaded. unleaded. 95 octane (RON) Mixture preparation Motronic MA 2.Technical Data R 850 GS R 1100 GS Fuel grade Super (premium). Throttle angle in rest position Air cleaner mm (in) 45 (1.772) 10 Circular paper element 13.772) ° 10 Circular paper element 45 (1.5 .2 Motronic MA 2. dia.2 Throttle stub pipe intl. 95 octane (RON) Super (premium).

unleaded.772) ° 10 Circular paper element 45 (1. 95 octane (RON) Mixture preparation Motronic MA 2. dia.Technical Data R 850 R R 1100 R Fuel grade Super (premium).6 mm (in) 45 (1.2 Throttle stub pipe intl. Throttle angle in rest position Air cleaner 13. unleaded.2 Motronic MA 2.772) 10 Circular paper element . 95 octane (RON) Super (premium).

Remove air cleaner box. Motorcycles with throttle-cable divider: disengage throttle cables. Detach return pipe from oil trap at air cleaner box (1). Install in the reverse order of work. Remove rear brake pipe from holder. Remove air cleaner cover. Remove front/rear air cleaner box. Separate connector between neutral switch and side stand switch and detach lead. Remove suspension strut. [ABS]/[GS/R/RT] Detach ABS sensor. [RS/GS/RT] Remove side sections of fairing. Unfasten intake pipe from throttle body. Remove brake fluid reservoir from holder. Remove rear muffler (silencer). Remove cable connector/wiring harness from air cleaner box. Disconnect plug for brake light switch and detach lead.1 RS130090 Removing and installing air cleaner • • • • • • • • • • • • • • • • • • • • Remove dualseat. Remove rear wheel.7 . Remove plug from air temperature sensor. 13. Remove air intake pipe. [ABS] Detach brake caliper. RS230310 • • • • Tilt rear frame upwards and secure with strap. • Unfasten screw connection on rear frame/only loosen mount at front of struts. Remove fuel tank. e Caution: Place support under rear wheel drive. [R] Remove the tank cover.

Install in the reverse order of work Adjusting choke. • • • Unfasten retainer (3) for fuel pipe and pull off the pipe.5 5 3 1 4 6 A 2 RS130100 Removing and installing throttle stub pipe • • Remove cover (1).8 • • Disconnect throttle cable (5) from the right. idle speed and synchronization See Group 00 a . Figure (A) Disconnect cable (6) for choke. Slacken off hose clips. Press in the spring catch on the multi-pin plug at the throttle position sensor (2) and pull off the plug. Slide intake connection into air cleaner box and remove throttle body. Motorcycle with throttle-cable divider. 13. e Caution: Make sure that the O-ring (4) at the throttle stub pipe is in good condition • • a L Note: Do not remove the throttle position sensor unless it has to be renewed (basic adjustment necessary— see Motronic diagnosis instructions). then from the left. throttle body.

Install in the reverse order of work. Remove connector strip. Press in the spring catch at the injector plug (5) and pull off the plug. 13. disconnect ground (earth) lead at battery and insulate it. • Removing and installing Motronic control unit • Remove fuel tank. Install in the reverse order of work. RS130010 • • • Remove Motronic control unit. e Caution: Make sure that O-rings at injector are in good condition.9 . e Caution: Switch off ignition.Removing and installing injectors • • • Unfasten retainer (3) for fuel pipe and pull off the pipe. Remove injector.

..1 ........10 Removing and installing fuel pump and fuel level sensor Checking fuel pump pressure ............................................ 3 Removing and installing fuel tank .....................................11 16.......................11 Removing and installing fuel distributor and pressure regulator ........................................16 16 Fuel tank and lines Contents Page Technical Data ....................................................................................................................................................................................................................................9 ...10 ................7 Removing and installing fuel filter.................................... fuel pump and fuel level sensor Removing and installing fuel filter .............................................

16.2 .

3 . pints/h) 12 3 (43.48) including reserve of l (Imp.56) Fuel pump Type Gear-type Make VDO Operating voltage Fuel pressure Delivery volume V bar (psi) l/h (Imp.6) 16. pints) 23 (40.16 Technical Data R 1100 RS Fuel tank Tank capacity l (Imp. pints) 6 (10.512) 110 (193.

512) 110 (193. pints/h) 12 3 (43.4 V bar (psi) l/h (Imp.6) . pints) 6 (10.75) including reserve of l (Imp.Technical Data R 1100 RT Fuel tank Tank capacity l (Imp. pints) 26 (45.56) Fuel pump Type Gear-type Make VDO Operating voltage Fuel pressure Delivery volume 16.

56) 6 (10.512) l/h (Imp. pints) 25 (44) 25 (44) including reserve of l (Imp.56) Fuel pump Type Gear-type Gear-type Make VDO VDO Operating voltage Fuel pressure Delivery volume V 12 bar (psi) 3 (43.6) 16.5 . pints/h) 110 (193.512) 110 (193.6) 12 3 (43.Technical Data R 850 GS R 1100 GS Fuel tank Tank capacity l (Imp. pints) 6 (10.

96) 21 (36.56) 6 (10. pints) 21 (36.56) Fuel pump Type Gear-type Gear-type Make VDO VDO Operating voltage Fuel pressure Delivery volume 16.Technical Data R 850 R R 1100 R Fuel tank Tank capacity l (Imp.6) .512) l/h (Imp.6) 12 3 (43. pints) 6 (10.95) including reserve of l (Imp.512) 110 (193.6 V 12 bar (psi) 3 (43. pints/h) 110 (193.

13 3 010... BMW No.. Remove fuel tank retaining screw (2).. [R] Remove fuel tank cover... loosen and pull off fuel feed and return line (3) with hose clip. Lift off fuel tank.... Separate plug connector (5) for fuel pump.... 22 Nm 16. Install in the reverse order of work.. [RS/GS/RT] Remove side sections of fairing.......RS 1 4 5 13 3 010 3 2 RS160010 Removing and installing fuel tank • • • • • • • • • • Remove dualseat.. X Tightening torque: Fuel tank to rear frame .. [RS] Detach inner cockpit panel (1) at fuel tank....7 .... Seal. Remove vent pipes (4)......

RT 6x C B A 13 3 010 3 4 B A C 5 6x RT160060 16.8 .

• • Drain fuel tank. fuel pump and fuel level sensor e Caution: Fuel is flammable and a hazard to health.2 1 RS160020 Removing and installing fuel filter. Remove fuel pump unit (1) and detach hoses (2).9 . Observe relevant safety regulations. 16.

.. 6 Nm 16.. Unscrew hose clip (4)... Tighten non-reusable hose clips with special pliers. BMW No.. Remove fuel pump..... X Tightening torque: Fuel pump assembly to tank .. Removing and installing fuel pump and fuel level sensor • • • • • Unfasten electrical connections (2) at fuel pump (3).. 13 1 500.10 .. After assembly... e Caution: Use only an O-ring (5) in good condition.1 4 3 2 5 RS160030 Removing and installing fuel filter e Caution: Note direction of fuel flow through filter (1).. Install in the reverse order of work.......... check fuel pump unit for leaks.

... check pump...... pressure regulator and fuel line. Removing gearbox Pressure regulator (1).Checking fuel pump pressure Removing and installing fuel distributor and pressure regulator 16 1 500 1 RS160050 RS160040 • • Connect test pressure gauge...... fuel filter.. 3 bar (43. BMW No.11 ... on the discharge side. 16 1 500... 16.. See Group 23....... • a • Remove air cleaner box.51 psi) L Note: If fuel pressure is low. Fuel pressure: Nominal value.... Run engine at idle speed....

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

2 .18.

... X Tightening torque: Oxygen sensor (Grease with Never Seez) .......3 ...... 20 Nm Clip on muffler (Grease clamping surface with Never Seeze) 50 Nm 1 • RS180050 • • [KAT] Detach fuel tank and pull it to rear.............................. 35 Nm [GS/R] Muffler at rear frame ... Install in the reverse order of work... e Caution: After trial run.....18 RS/RT 5 GS/R 2 3 RS180020 Removing and installing exhaust system Removing and installing muffler (silencer) • • • • • • Loosen pipe clip (2).... e Caution: Note position of wiring for oxygen sensor.... Unfasten retaining screws (3). X Tightening torque: RS/RT] Muffler to footrest . Remove rear muffler... read out Motronic fault memory. [GS/R] Unscrew the rear pipe clip.. [CAT] Remove and install oxygen sensor (5).... e Caution: Do not pull the oxygen sensor cable.... 24 Nm Muffler to support plate for center stand ..... Separate plug connector (1) for oxygen sensor and detach cable.............. [RS/RT] Take off the retainer at the rear muffler mount. 55 Nm 18..

. L Note: When installing.... 22 Nm Front exhaust pipes (with outer pipe) at cylinder head.. Install in the reverse order of work........ Unscrew exhaust pipe mount (6)...................4 .... use new seals (7)... 18 Nm Clip at muffler (coat clamping surface with Never Seez) .......... 50 Nm 18.6 7 2 7 6 RS180030 Removing and installing front exhaust pipes • • • • Loosen pipe clip (2). Take off front exhaust pipes.. X Tightening torque: Front exhaust pipes (with plate) at cylinder head ...

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

21.2 .

Wear dimension mm (in) 180 (7.276) Distance for basic clutch adjustment (free thread length at adjusting screw on handlebar lever) mm (in) 12 (0.5 (0.472) 21.3 . with release lever and thrust rod passing through hollow gearbox shaft Clutch plate dia.0879 mm (in) 4.177) (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 (0.21 Technical Data R 1100 RS Type of clutch Single dry plate with increased-leverage diaphragm spring Operation Mechanical.

5 (0.Technical Data R 1100 RT Type of clutch Single dry plate with increased-leverage diaphragm spring Operation Mechanical. with release lever and thrust rod passing through hollow gearbox shaft Clutch plate dia.276) Distance for basic clutch adjustment (free thread length at adjusting screw on handlebar lever) mm (in) 12 (0. Wear dimension mm (in) 180 (7.472) 21.0879 mm (in) 4.4 . pressed together by hand) Manual effort required Nm 65 Clutch operating clearance at handlebar lever mm (in) 7 (0.177) (measured on rivets of clutch plate using tips of sliding caliper.

177) (measured on rivets of clutch plate using tips of sliding caliper.5 . with release lever and thrust rod passing through hollow gearbox shaft Clutch plate dia.0879 mm (in) 4.5 (0.177) 4.276) Distance for basic clutch adjustment (free thread length at adjusting screw on handlebar lever) mm (in) 12 (0.Technical Data R 850 GS Type of clutch Single dry plate with increased-leverage diaphragm spring Operation Mechanical.0879 180 (7. pressed together by hand) Manual effort required Nm 65 65 Clutch operating clearance at handlebar lever mm (in) 7 (0.5 (0.276) 7 (0. Wear dimension R 1100 GS mm (in) 180 (7.472) 21.472) 12 (0.

276) 7 (0.472) 12 (0. Wear dimension R 1100 R mm (in) 180 (7.177) (measured on rivets of clutch plate using tips of sliding caliper.5 (0. with release lever and thrust rod passing through hollow gearbox shaft Clutch plate dia.Technical Data R 850 R Type of clutch Single dry plate with increased-leverage diaphragm spring Operation Mechanical.276) Distance for basic clutch adjustment (free thread length at adjusting screw on handlebar lever) mm (in) 12 (0.6 . pressed together by hand) Manual effort required Nm 65 65 Clutch operating clearance at handlebar lever mm (in) 7 (0.0879 mm (in) 4.472) 21.177) 4.0879 180 (7.5 (0.

Remove air cleaner cover. release Bowden-cable divider. Detach return line/oil trap from air cleaner box. then the negative terminal. Remove plug from air temperature sensor. Remove front/rear air cleaner box. Connect the positive battery terminal first. 13 0 010. Remove air cleaner box. Disconnect plug for brake light switch and detach lead. Unfasten screw connection on rear frame/only loosen mount at front of struts. 21. Remove fuel tank. [RT] Remove mirror. RS230310 • • • • • • • • • • • Tilt rear frame upwards and secure with strap (1). Detach air intake pipe and push it into the air cleaner housing. Remove suspension strut. [RS/GS/R] Take off starter motor cover/pull off wire to power socket. Remove battery. Seal. Separate plug for fuel pump. [ABS] Detach rear brake caliper. Remove cable connector/wiring harness from air cleaner box. Remove starter motor. Unfasten plug connector for neutral switch and side stand switch/detach leads. BMW No. Unscrew fuel tank mount. loosen and pull off fuel feed and return line with hose clip. Remove vent pipes. Remove rear brake pipe from holder. Remove muffler. Disconnect clutch cable from gearbox. Unscrew rear battery mount. [ABS]/[GS/R/RT] Detach the plug connection at the rear sensor line and the line itself. [RS/GS/RT] Remove side sections of fairing. • • • • • • • • • • • • • • Motorcycles with throttle-cable divider. [R] Remove fuel tank cover. then positive terminal. Remove brake fluid reservoir from holder.Removing and installing clutch 1 • • • • • • • • • • • Remove dualseat. [RS] Detach inner cockpit panel at fuel tank. Detach leads at starter motor. e Caution: Disconnect negative terminal from battery first.7 . Unfasten/remove fuel pipe from injector. [ABS] Take off right footrest plate.

e Caution: Hold gearbox at installation height until entire clutch push rod is visible. 23 1 820 23 1 820 RS230011 • • Locate the gearbox when removing and installing with oiled guide pins. 21. to side stand switch. for throttle angle sensor. • Install in the reverse order of work. BMW No. or else this may be bent. for injector. rear wheel drive unit and swinging arm together with gearbox.• • • • Detach Detach Detach Detach lead lead lead lead to oil pressure switch. Remove rear wheel.8 . 23 1 820.

..2 2 4 1 11 5 640 RS210011 Removing clutch • • Lock the clutch housing with retaining device (1)................... 11 5 640............................. X Tightening torque: Lubrication points: Splines on clutch plate and input shaft Diaphragm spring contact surface at clutch housing Diaphragm spring contact surface at driven plate ..... • • • Secure clutch with retaining screws (4)...................... 18 Nm Clutch housing to crankshaft (oil screw threads lightly) Initial tightening .....9 .... Tighten retaining screws alternately in a crosswise pattern... 32° • Install clutch.................... Center the clutch plate with centering pin..... BMW No. 40 Nm Wrench angle ............ • • • Install clutch housing with mark (2) aligned with crankshaft mark (2).... 11 5 640...... Optimoly MP3 paste X Tightening torque: Housing cover to flywheel .... BMW No..... 21 3 680.. Always use new bolts for housing and cover..... 21.. Lock the clutch housing with retaining device (1)....... BMW No. Installing clutch e Caution: e Caution: Offset the color marks on the clutch housing........... Insert all screws by hand and tighten down......... Remove clutch. driven plate and housing cover through 120° in each case.......

. detach the power socket holder.10 X Tightening torque: Locknut on adjusting screw ......... Using socket wrench.... BMW No......... 21. Distance B: ......... 31 5 600.. 21 3 610....... 7 mm (0. 22 Nm .. BMW No.Adjusting clutch operating clearance B A RS210040 • RS210020 Set to distance B at the handlebar lever by turning adjusting screw (2) on the clutch release lever.. 12 mm (0........... detach the hydraulic spring adjusted with a 6 mm (0........472 in) 21 3 610 2 1 RS210030 • • • [GS] If necessary...24 in) Allen key........276 in) • Turn adjusting screw to obtain distance A........ Distance A:.. [RT] If necessary......... loosen locknut (1) for adjusting screw (2) at clutch release lever.............

.......................................................17 Removing and installing selector shaft seal ...........................................................................17 Removing and installing shift pawls ..................1 ...........................................................10 .......................18 Installing deep-groove ball bearing on selector drum ......................7 Removing and installing clutch bear-ing/thrust rod/release lever Removing and installing gear shift pedal Removing gearbox ....................................................13 Removing selector drum ..........................................................................................................................................................................................................................................................23 23 Gearbox Contents Page Technical Data ....................12 Replacing shaft seal on neutral switch .....10 Dismantling/reassembling .......................................................................................................................14 Removing gearbox shafts ..................................17 Removing and installing torsion spring ..18 Removing taper roller bearing race from input shaft and roller bearing from idler shaft ............17 Removing deep-groove ball bearing from selector drum .............................................................23 23.............................................................................18 Shimming selector drum ...........................................................................................................................................................................................................................................................................................................................................................19 Removing and installing deep-groove ball bearing and race/roller bearing for idler shaft ..................................................................................................................................................................21 Disassembling/assembling input shaft (Clean Bearing) .......................................................................9 ..............................15 Removing and installing input shaft sealing ring at housing end ...................................................................................................................................................................................................19 Installing taper roller bearing race on input shaft and roller bearing for idler shaft ........................................... 3 Gearbox ....................sectioned drawing ..................................12 Removing gearbox cover .....................................................................20 Dismantling/reassembling input shaft ....................................................................................16 Removing and installing detent lever ..........15 Removing/dismantling/reassembling selector shaft ...............................................................................................................................................................................

......................................................................................................................................................31 Installing selector forks ............................29 Removing and installing output shaft seal ....................................33 Measuring gearbox cover ......................................................35 Example ........................................................................................34 Shimming the gearbox shafts (without Clean Bearing) ................................30 Installing selector shaft ............36 Installing gearbox cover ...........................................................................36 Checking friction coefficient of input shaft taper roller bearing ..........................................................................................Contents Page Dismantling/reassembling output shaft ......................................................................................................................................................................................35 Shimming the gearbox shafts (with Clean Bearing) ......................................................................................................................................................................................................................................................................................................................................................................25 Removing spur gears .....................25 Removing deep-groove ball bearing ..32 Installing selector drum ............................................................................................................................................................................................................33 Measuring shaft bearing play ..37 Removing and installing input shaft seal at housing cover end Completing assembly of gearbox Installing gearbox 23...................................................35 Example ...............................................................................................................................................................................................................................39 ...........................................................................................................2 .......................................40 ............................................................................................35 Removing and installing taper roller bearing race ..............................................................................................................26 Installing spur gears .......38 .................27 Installing gearbox shafts ...................................................................................32 Shimming gearbox shafts ..........

0.8 (1. .0 Nm frictio End float at selector drum/deep-groove ball bearing mm (in) < 0.2 mm (0.0..5.227 As of gearbox No. pints) 1.00196.0.0059) End float.133 4th gear 1.00196..0. pints) approx.0 (1.325.0059) Preload on input shaft 0.15 (0.M94) 1st gear 4...0.23 Technical Data R 1100 RS Type of gearbox 5-speed gearbox with claw-action shift and integral reaction damper for all gears Type of selector mechanism Pedal-operated lever and selector drum with overshoot detent Gear ratios up to 1993 model year 1st gear 4.222..740 5th gear 1...05..318 Gear ratios from 1994 (gearbox No.538 5th gear 1.15 (0.05..3 ..0039) End float at deep-groove ball bearing/housing mm (in) < 0..886 4th gear 1.76) (to lower edge of filler screw) When oil is changed l (Imp..00196.1.. input shaft (Clean Bearing) mm (in) 0. 101 DAQ 101 DAR 101 DAS 101 DAT 101 DAU 101 DAV 101 DCQ 101 DCR 23.00787) = 0.163 2nd gear 2.408) (to lower edge of filler screw) End float on idler shaft mm (in) 0..05.576 3rd gear 1.914 3rd gear 2..0059) End float on output shaft mm (in) 0..1 (0.0.030 2nd gear 2..: 2..1 (0.. 10483 DAF 10776 DAH 12958 DAK 12650 DAL 12405 DAG 7864 DAJ 131 DCF 101 DCH Full conversion to Clean Bearing BMW No.. 0.450 Oil grade (all the year round) Brand-name SAE 90 hypoid gear oil.15 (0. API Class GL 5 Filling capacity Initial filling l (Imp.0039) Input-shaft conversion to Clean Bearing As of gearbox No.

740 5th gear 1.15 (0.0.4 .227 As of gearbox No.1 (0.163 2nd gear 2...450 Oil grade (all the year round) Brand-name SAE 90 hypoid gear oil..0.5.05..05...00787) = 0.8 (1.133 4th gear 1.15 (0.Technical Data R 1100 RT Type of gearbox 5-speed gearbox with claw-action shift and integral reaction damper for all gears Type of selector mechanism Pedal-operated lever and selector drum with overshoot detent Gear ratios from 1994 (gearbox No.222.0.0 Nm frictio End float at selector drum/deep-groove ball bearing mm (in) End float at deep-groove ball bearing/housing mm (in) < 0. input shaft (Clean Bearing) mm (in) 0..1 (0..0039) < 0. pints) 1. API Class GL 5 Filling capacity Initial filling l (Imp.00196. 101 DAQ 101 DAR 101 DAS 101 DAT 101 DAU 101 DAV 101 DCQ 101 DCR 23. 0.0 (1.00196.: 2.15 (0..325...0..00196..0039) Input-shaft conversion to Clean Bearing As of gearbox No.0..408) (to lower edge of filler screw) End float on idler shaft mm (in) 0.76) (to lower edge of filler screw) When oil is changed l (Imp..914 3rd gear 2. 10483 DAF 10776 DAH 12958 DAK 12650 DAL 12405 DAG 7864 DAJ 131 DCF 101 DCH Full conversion to Clean Bearing BMW No. . pints) approx....05.1..M94)) 1st gear 4.0059) Preload on input shaft 0..0059) End float on output shaft mm (in) 0.0.2 mm (0.0059) End float.

133 2. input shaft (Clean Bearing) mm (in) 0.15 (0.0. 101 DAQ 101 DAR 101 DAS 101 DAT 101 DAU 101 DAV 101 DCQ 101 DCR 23....76) (to lower edge 1..0039) < 0.0.8 (1.740 1.0059) End float.0 (1.450 1.1 (0.15 (0..15 (0..0039) < 0.05.1 (0..0059) Preload on input shaft 0.0039) Input-shaft conversion to Clean Bearing As of gearbox No.Technical Data R 850 GS R 1100 GS Type of gearbox 5-speed gearbox with claw-action shift and integral reaction damper for all gears Type of selector mechanism Pedal-operated lever and selector drum with overshoot detent Gear ratios 1st gear 4..0 Nm frictio End float at selector drum/deep-groove ball bearing mm (in) < 0...05.00196.0.00787) = 0.408) (to lower edge of filler screw) End float on idler shaft mm (in) 0..1 (0.5 .00787) = 0.. 10483 DAF 10776 DAH 12958 DAK 12650 DAL 12405 DAG 7864 DAJ 131 DCF 101 DCH Full conversion to Clean Bearing BMW No...15 (0.0059) End float on output shaft mm (in) 0..00196.2 mm (0.0.914 3rd gear 2.133 4th gear 1..0...0059) 0.15 (0.05.5.740 5th gear 1. pints) 1.0059) 0.05. pints) approx.. API Class GL 5 Filling capacity Initial filling Initial filling l (Imp..0.2 mm (0..0.00196.914 2.0.05..0039) End float at deep-groove ball bearing/housing mm (in) < 0.0..0 (1...408) (to lower edge of filler screw) When oil is changed approx.76) (to lower edge of filler screw) of filler screw) When oil is changed l (Imp.0 Nm frictio 0.. 0.0059) 0..0.325.1.15 (0.8 (1.: 2...1 (0. 0. API Class GL 5 Brand-name SAE 90 hypoid gear oil.227 As of gearbox No.0.0.05.00196.5.450 Oil grade (all the year round) Brand-name SAE 90 hypoid gear oil..1.163 4.00196.163 2nd gear 2.00196.222.

.00196.0.0.450 Oil grade (all the year round) Brand-name SAE 90 hypoid gear oil.1 (0. 0..0 (1...408) (to lower edge of filler screw) When oil is changed approx.15 (0..914 3rd gear 2..408) (to lower edge of filler screw) End float on idler shaft mm (in) 0.0.15 (0.0 (1.0059) 0. API Class GL 5 Brand-name SAE 90 hypoid gear oil. API Class GL 5 Filling capacity Initial filling Initial filling l (Imp.00196..0 Nm frictio End float at selector drum/deep-groove ball bearing mm (in) < 0.0.00196..05.1 (0.76) (to lower edge 1.. input shaft (Clean Bearing) mm (in) 0.325...740 1.76) (to lower edge of filler screw) of filler screw) When oil is changed l (Imp.15 (0... pints) 1.0..05.2 mm (0.: 2.5.914 2. 10483 DAF 10776 DAH 12958 DAK 12650 DAL 12405 DAG 7864 DAJ 131 DCF 101 DCH As of gearbox No....05.1 (0.133 2.163 2nd gear 2.00196.6 .. 101 DAQ 101 DAR 101 DAS 101 DAT 101 DAU 101 DAV 101 DCQ 101 DCR As of gearbox No.0059) End float..15 (0. 101 DAQ 101 DAR 101 DAS 101 DAT 101 DAU 101 DAV 101 DCQ 101 DCR 23..0039) < 0.0.0.0039) < 0.0 Nm frictio 0.1.163 4.05.00787) = 0.0..227 As of gearbox No......0.05.0.15 (0.8 (1.0.0059) 0.133 4th gear 1..0.15 (0. 10483 DAF 10776 DAH 12958 DAK 12650 DAL 12405 DAG 7864 DAJ 131 DCF 101 DCH Full conversion to Clean Bearing BMW No.00196.5...0039) End float at deep-groove ball bearing/housing mm (in) < 0.0059) 0.2 mm (0.1.740 5th gear 1.0039) Input-shaft conversion to Clean Bearing As of gearbox No.Technical Data R 850 R R 1100 R Type of gearbox 5-speed gearbox with claw-action shift and integral reaction damper for all gears Type of selector mechanism Pedal-operated lever and selector drum with overshoot detent Gear ratios 1st gear 4.00196..05.0059) Preload on input shaft 0.222.1 (0.8 (1. pints) approx.00787) = 0. 0.450 1.0059) End float on output shaft mm (in) 0.

7 .sectioned drawing RS239010 23.Gearbox .

8 .23.

. L Note: Check/adjust clutch operating clearance. Remove release lever (1).. 120 °C /remove. 120 °C /remove...9 . make sure that it moves freely....... • Install in the reverse order of work.. Lubricating points (arrow): . Withdraw clutch thrust rod (6). is not worn and is adequately greased. Remove rear wheel drive assembly/heat pivot pin to max....... Remove sleeve and spring (3/4).Optimoly MP3 compound 23... L Note: Check clutch release bearing at piston (5).. Remove clutch piston (5). [RT] Remove the footrest plates.. Remove swinging arm and drive shaft/heat pivot pin to max.... Remove rear wheel. Unscrew clip (2). Disconnect clutch cable from release lever.......1 6 3 2 4 5 RS230021 Removing and installing clutch bear-ing/thrust rod/release lever • • • • • • • • • • • • Unfasten and remove brake caliper. [ABS]/[GS/R/RT] Detach plug connector for rear sensor and wire.........

... [RS] Detach inner cockpit panel at fuel tank.. X Tightening torque: Gear shift pedal to footrest plate [RS/GS/R] ............. Separate connector between neutral switch and prop stand switch and detach lead. Unscrew fuel tank mount.. • • • • • • • • • • • 23............. Remove air cleaner cover...... BMW No....... [ABS] brake master cylinder . then the negative terminal.. then the positive terminal... Remove fuel tank.. Unscrew rear battery mount...... Connect the positive battery terminal first.. 13 0 010... Remove battery.. Remove retaining screw (2) on gear shift pedal.... 35 Nm [RT]. loosen and pull off fuel feed and return line using hose clip.........Removing and installing gear shift pedal 2 Removing gearbox • • • • • • • • • • 1 e RS230321 • • Remove retaining bracket (1) and unfasten ball head.. Seal.... [R] Remove fuel tank cover. Remove vent pipes..... Detach air intake pipe and push it into the air cleaner box........ Motorcycles with throttle-cable divider. Remove connector from brake light switch and lead. [RS/GS/RT] Remove side sections of fairing..10 Remove dualseat.... Separate plug for fuel pump.. Remove plug from air temperature sensor. .............. 18 Nm Caution: Disconnect the negative battery terminal first. Remove muffler... release Bowden-cable divider.detach at footrest plate. [ABS]/[GS/R/RT] Disconnect the plug for the rear sensor line and the wire itself..... Unfasten air cleaner box at front and rear.........

Remove rear wheel. Unfasten fuel line from injector and remove.11 . Disconnect clutch cable from gearbox. Remove cable connector/wiring harness from air cleaner box. 23. BMW No. 23 1 820 Tilt rear frame upwards and secure with strap. [RS/GS/R] Detach starter motor cover and pull off wire to power socket.• • • • • • Remove brake fluid reservoir from holder. Unfasten rear frame screw connections but only loosen front strut mounts. Remove rear wheel drive unit. Detach return line/oil trap from air cleaner box. Detach cable from starter motor. 120 °C/ loosen. Detach injector cable Detach throttle angle sensor cable. Heat rear wheel drive pivot pin to max. Take off the footrest plates. Press off drive shaft. Remove rear brake pipe from holder. Detach side stand switch cable. Detach retaining clip from ball head/shift linkage and remove ball head. Detach oil pressure sensor cable. pull it out on guide pins. Unfasten strut at gearbox housing. 120 °C and remove. 23 1 820 RS230011 • When removing gearbox. 23 1 820. Remove suspension strut. • • • • • • • • • • • • • • • • • • RS230311 • Remove rear brake caliper. Remove swinging arm/heat pivot pin to max. Remove air cleaner box.

. to assembly stand. Secure gearbox with assembly fixture.. insert the shaft seal fully. Remove retaining ring (3) from selector drum. Remove neutral switch (2).... spring facing oil chamber .......12 Replacing shaft seal on neutral switch • • Remove shaft seal using a suitable tool..... Using light fingertip pressure........ coil spring (7) and clutch piston (8). BMW No.... 23........ Unfasten hose clip (5). Remove clutch thrust rod (1)..4 1 6 5 7 8 2 3 23 1 610 R230020 Dismantling/reassembling • • • • • • • • Drain gearbox oil. 23 1 610.... Direction of installation: . Unfasten retaining screw on clutch lever (4)... Remove sleeve (6).

Press off gearbox cover evenly. BMW No. on the input shaft. Remove ball (3) from neutral stop.j 100 4 23 4 632 1 2 5 6 3 Clean Bearing RT230032 Removing gearbox cover • • • • • • • Unfasten screw (1) for idle speed detent and remove coil spring (2). Remove retaining screws from gearbox cover. Remove spacers (5)/oil baffle plate (6). 23 4 632. Place sliding sleeve. Heat gearbox cover to 100 °C at the bearing seats. e Caution: Do not accidentally confuse spacers! 23.13 .

23. Turn selector forks outwards. Position pawl (2) opposite recess in selector drum. Remove selector forks.1 Clean Bearing 4 2 3 RT230041 Removing selector drum • • • Withdraw selector fork shafts (1) from gearbox housing. turning it slightly at the same time.14 . L Note: Avoid damage to rollers (4) on guide pins of selector forks. • • Withdraw selector drum (3).

Drive in the sealing ring with a drift and guide sleeve.. Place sliding sleeve (3). BMW No. on output shaft. [1993 model year] Pull input shaft (2) out of gearbox housing. [from 1994 model year on] Pull the input. BMW No. BMW No. 23 4 622. and with handle. 23 4 650. 00 5 500. idler and output shaft out of the gearbox housing together. Removing and installing input shaft sealing ring at housing end 00 5 500 23 4 650 23 4 650 RS230051 • • Force shaft seal inwards using drift.15 . [1993 model year] Pull the idler and output shaft (4) out of the gearbox housing together. 23.1 4 2 Clean Bearing j 100 3 23 4 622 RT230051 Removing gearbox shafts • • • • • • • • Remove oil baffle plates (1). Heat output shaft bearing point to 100 °C [Clean Bearing input shaft] Heat bearing journals of input shaft and output shaft to 100 °C [Full Clean Bearing kit] Heat all 3 bearing journals to 100 °C.

16 . and pull out selector shaft with washer (3). BMW No. 23 4 612. Attach sliding sleeve (2).3 2 1 23 4 612 RS230060 Removing/dismantling/reassembling selector shaft • • Remove selector shaft (1). 23.

23 4 611 • • 1 Removing and installing torsion spring • Remove retaining ring (6). • Remove keeper (2). working from the inside Drive in the seal with drift. 23 4 611. Install bearing bushing. 23. • Remove stop lever (3) with spring and washer. RS230100 • • • • Remove bearing bushing (1) from sliding seat. Removing and installing selector shaft seal Removing and installing shift pawls Remove keeper (4). BMW No.1 2 3 4 7 5 6 RS230071 Removing and installing detent lever • Remove washer (1). • Remove torsion spring (7) with washers. Force out shaft seal with drift.17 . Remove pawl (5) and spring from pawl holder.

BMW No.. 00 8 561.. Heat gearbox housing to 100 °C. if necessary using counter-support.. End-play: .. L Note: Retaining ring must locate firmly in groove. 00 8 573. 00 8 572. BMW No..0039 in) • If necessary...18 Heat gearbox housing to 100 °C.. Measure clearance with feeler gage. RS230110 • • Shimming selector drum • • RS230130 • Fit deep-groove ball bearing.. the bearing races may already slide out of their seat when the housing is heated.. if necessary with countersupport.... BMW No.. BMW No.. deep-groove ball bearing will slide out of seat... Pull out taper roller bearing race. 23. width 1. < 0. Pull out roller bearing. .Removing deep-groove ball bearing from selector drum j Removing taper roller bearing race from input shaft and roller bearing from idler shaft 100 j 100 RS230120 • • • Remove retaining ring and spacers. Depending on tolerance. use a wider retaining ring to eliminate play.....0 mm (0..1 mm (0... 00 8 562.... When heated.. • • Install retaining ring. and internal puller... and internal puller.039 in).

. and handle.. RS230142 • Shim out bearing (zero backlash)/insert retaining ring.. 23 4 640. Note different diameters of taper roller bearing outer races on input shaft. BMW No.... BMW No..1 mm (0. BMW No.... < 0... e Caution: RS230143 • • • Bearing must be firmly located. 00 5 500. insert the deepgroove ball bearing.. 00 5 500....... Using drift. and handle. Insert roller bearing with drift. 23 4 660.. BMW No. Heat gearbox housing to 100 °C.. e Caution: Bearing must be firmly located... End-play: ..19 ..Installing deep-groove ball bearing on selector drum j Installing taper roller bearing race on input shaft and roller bearing for idler shaft 100 23 4 640 00 5 500 23 4 660 00 5 500 23 4 670 RS230141 • • Heat gearbox housing to 100 °C. BMW No.. 23 4 670....0039 in) 23. Insert taper roller bearing race with drift..

drive further on by striking inner race only. To install deep-groove ball bearing or race/roller bearing. heat to 80 °C and push into position. e Caution: If necessary. e Caution: Be careful of the sealing washer as you heat the bearing (Clean Bearing).Removing and installing deep-groove ball bearing and race/roller bearing for idler shaft L Note: If defective. the complete idler shaft must be replaced. BMW No. 23. 00 7 500 RS230181 • • Pull off deep-groove ball bearing or race/roller bearing with universal puller. 00 7 500.20 . risk of damage.

Remove washer (6). BMW No. Slide coil spring (5). pressure piece (4) and spur gear (3) onto shaft. 00 7 500. pressure piece (4) and spur gear (3). Relieve tension on retaining ring (1).6 7 1 2 3 4 5 RS230150 Dismantling/reassembling input shaft • • • • 00 7 500 • Using a universal puller.21 . Remove retaining ring/washer (1) 23. Slide on washer (6) with chamfer facing the end away from the spring. Pull off the taper roller bearing (7) in the same way. RS230160 • • • Clamp input shaft spline in vise with chuck jaws. if necessary with gentle blow on bearing inner race. coil spring (5). and pressure head (arrow). pull off spur gear (3) together with taper roller bearing (2).

RS230171 • Fit universal puller under spur gear and press taper roller bearing firmly against retaining ring. or heat it to 80 °C and position it on the input shaft. drive further on by striking inner race only. press on taper roller bearing cold. L Note: If the input shaft has to be shimmed again.00 7 500 00 7 500 7 RS230170 • • Use universal puller to tension spur gear against coil spring until entire step (arrow) protrudes from the spur gear. To install using a press. 23. • Install retaining ring/washer (1) in front of taper roller bearing. e Caution: To prevent measuring errors when installing shims later. e Caution: If necessary. zero backlash is required between bearing and retaining ring. e Caution: If necessary. or heat it to 80 °C and position it on the input shaft. do not install taper roller bearing (7) until measuring work is complete. press on taper roller bearing (7) cold.22 . • Using a press. drive further on by striking inner race only.

95 42 x 52 x 1.25 42 x 52 x 0.40 42 x 52 x 0.08 (1.5 20 x 1.00393) do not install 42x52x1.898+ 0.23+ 0.05x0.65x2.65x2. If DAn = 41.08 (3.00315)) install a 42x52x1.00315 ) and GAn = 100.85 20 x 1.1 (1.00393 ) and GAn = 99.65x2. Calculate distances DAn and GAn. 23.35 42 x 52 x 0. If DAn = 39.28+ 0.25 (1.7 8 2 1 3 4 5 6 42 x 52 x 1.75 20 x 1.049) washers are installed only for the “interim solution”. Note: The 42x52x1.25 (1.45 42 x 52 x 0.049) washer for each.25 (1.1 (3.05x0.946+ 0.50 42 x 52 x 0.30 42 x 52 x 0.0+ 0.5+ 0.625+ 0.55 25 x 52 x 15 20 x 52 x 15 20 x 28 x 0.25 RT230151 Disassembling/assembling input shaft (Clean Bearing) L.05x0.23 .555+ 0.049) washers.

Slip spring (6). Press on bearing (3) cold. Remove bearing (8) in the same way. apply pressure to the inner ring only. make sure that there is no clearance between bearing and locking ring. . risk of damage. remove spur gear (4) complete with bearing (3). drive further on by striking inner race only. e Caution: If necessary. or heat to 80 °C (176 °F) and position on input shaft. • • • Install spacer (2). L Note: If input shaft has to be shimmed. e Caution: If the Clean Bearing input shaft is installed. spring (6). using press. e Caution: When seating components on the input shaft while removed from engine. e Caution: Be careful of the sealing washer as you heat the bearing (Clean Bearing). Using universal puller. Install locking ring (1) and make sure that assembly is free of play.24 • By preference. and thrust adapter (arrow) to apply uniform pressure. thrust piece (5) and spur gear (4). if necessary lightly tap bearing inner ring to release. do not install grooved ball bearing (8) until all measurements have been completed. drive further on by striking inner race only.. risk of damage.• Clean Bearing 00 7 500 Press on grooved ball bearing (8) cold. the bearing might no longer be correctly seated on the locking ring. RT230161 • • • • • • • • • Clamp splined end of input shaft in vice fitted with jaw protectors. BMW No. Remove locking ring and washer (1/ 2). e Caution: Be careful of the sealing washer as you heat the bearing (Clean Bearing). Remove washer (7). Position universal puller under spur gear and seat bearing against locking ring e Caution: In order to avoid measuring errors when shims are subsequently installed. e Caution: If necessary. using press. risk of damage. Slip washer (7) into position with bevel facing away from the spring. or heat to 80 °C and position on input shaft. thrust piece (5) and spur gear (4) onto shaft. do not strike shaft/bearing as otherwise. 00 7 500. Relieve strain on locking ring (1). press on grooved ball bearing (8) cold. e Caution: Be careful of the sealing washer as you heat the bearing (Clean Bearing). using press. 23. or alternatively heat to 80 °C (176 °F) and position on input shaft.

[from 1994 model year] Measurement and adjustment of G are no longer needed.8-0. BMW No. 00 7 500. adjust distance G with shims. if necessary. 23.1 RS230191 Dismantling/reassembling output shaft • • Removing deep-groove ball bearing [1993 model year] When determining total distance G. and pressure head.1 G=125. 00 7 500 RS230192 • • Clamp the output shaft into a vise with soft jaws. Using universal puller. pull off the deep-groove ball bearing. include spacing washer (1).25 .

Remove toothed disk (13) and retaining ring (14). Remove spacer (7) and bearing bushing (6) with spur gear for 4th gear (8). Remove toothed disk (10). Remove split needle cage (12). [from 1994 model year on] take off the O-ring (15). [from 1994 model year on] Take off O-ring (16). 23.1 8 6 15 7 2 3 4 5 RS230193 Removing spur gears • Remove spur gear for 1st (1) and 5th gear (2) with thrust washers. 3 4 16 5 10 9 11 14 RS230194 • • • Remove thrust washer (4) and bearing bushing (3) with spur gear for 3rd gear (5).26 • • • • • • 13 12 RS230195 Remove retaining ring (9). . Remove spur gear for 2nd gear (11).

or heat to 80 °C and position on input shaft. e Caution: If necessary. Fit thrust washer. Slide spur gear for 3rd gear (5) onto output shaft with apertures facing upwards. [from 1994 model year on] Push O-ring (16) onto seat. with apertures at top. e Caution: Be careful of the sealing washer as you heat the bearing (Clean Bearing). then retaining ring (9). e Caution: RS230198 • • • • Use a new O-ring. 23. Slide on retaining ring (14) and locate in groove. Press on grooved ball bearing cold. Fit thrust washer. • • • • • • Fit split needle cage (12) to output shaft. First slide spur gear for 2nd gear (11) over needle cage. the drive shaft splines must face upwards.27 .Installing spur gears 2 16 10 9 5 11 14 13 12 RS230195 • • • Slide toothed disk (13) up to front of bearing seat. risk of damag. using press. drive further on by striking inner race only. Fit spur gear for 5th gear (2) with dogs facing downwards. Clamp output shaft into vise with soft jaws. Heat the wide race (3) to 80 °C and push it onto the output shaft as far as the support washer. Install toothed disk (10).

e Caution: Use a new O-ring. Slide spur gear for 1st gear (1) onto output shaft with aperture and shift teeth facing downwards. using press. e Caution: Be careful of the sealing washer as you heat the bearing (Clean Bearing). Fit spacer (7). e Caution: If necessary.1 RS230190 • • • • Invert output shaft in vise with spline tracks facing downwards. [from 1994 model year on] Push O-ring (15) onto seat. or heat to 80 °C and position on input shaft. [1993 model year] Heat the narrow race (6) to 80 °C and push it onto the output shaft as far as the spacing washer. Slide spur gear for 4th gear (8) onto output shaft with dogs facing downwards. RS230199 • • • • • • [1993 model year] Measure distance G and shim as necessary. Fit thrust washer.28 . risk of damage.8-0. drive further on by striking inner race only. 23. [from 1994 model year on] Heat the narrow race (6) to 80 °C and push it on flush with the step in the shaft. Press on grooved ball bearing cold.j1 7 8 80 6 15 G=125.

[1993 model year] Insert the idler shaft and output shaft (3) into the gearbox housing together. idler and output shafts into the gearbox housing together. [Clean Bearing] Install spacer (5)...29 .. also apply Loctite 573 to the sealing face on the oil baffle plate where it contacts the gearbox housing) .. onto the output shaft........ BMW No... • • • • • a • • Heat the output shaft bearing point to 100 °C.. e Caution: After installation of the oil baffle plates. • Install oil baffle plates (4). 23 4 622.. With gentle blows of a plastic-faced hammer... Push sliding sleeve (2). turn the gears and check for ease of movement. do not install the input-side bearing until all measurements have been completed. as otherwise the bearing might no longer be correctly seated on the locking ring.1 3 Clean Bearing Clean Bearing v v 4 5 2 j 100 23 4 622 RT230201 Installing gearbox shafts L Note: If the input shaft has to be shimmed. check that bearing is firmly seated.... X Tightening torque: Oil baffle plate retaining screws (clean thread + Loctite 573.22 [from 1994 model year on] Insert the input. e Caution: Do not strike the seat of a Clean Bearing shaft... [1993 model year] First insert the input shaft (1).. 9 Nm 23. page 23.

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

2
23 4 612

1

23 4 612

RS230230

Installing selector shaft

Insert selector shaft with sliding sleeve (1),
BMW No. 23 4 612.

B

L
Note:
Note washer (2).

1

A

RS230340

[RS/R] Attach gear shift pedal (1) horizontal, noting distance B.

Maß „B“: .............. 61.2 ±1.8 mm (2.409 ±0.07 mm)

1
RT230330

X
Tightening torque:
Gear shift pedal.............................................. 9 Nm

[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)

23.31

Clean Bearing

4
1
5
3

2
RT230221

Installing selector forks

Installing selector drum

L Note:

Swing the selector forks over to the edge of the
housing.
Install selector drum with its recess facing the
selector shaft pawl (5).

Fit rollers (1) on guide pins and apply some grease
to the pins.

L
Note:
If necessary, secure needle rollers with grease.


Install selector fork (2) for 5th gear in underside
of output shaft with short end of guide facing upwards.
Install selector fork (3) for 1st and 2nd gears with
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 downwards.

23.32


Insert selector fork guide pins into selector drum.
Install shift fork shafts.

00 2 550

23 4 600

RS230240

Shimming gearbox shafts
Measuring shaft bearing play
• Bolt gearbox measuring plate,
BMW No. 23 4 600, to the sealing face, which
must be clean.

GAn
GAb

GZw

Tightening torque: ........................................ 9 Nm

Using depth gauge, BMW No. 00 2 550, measure distance between measuring plate and outer
race of deep-groove ball bearing.

L Note:

Before measuring, strike the shaft in question (output/idler shaft) with a plastic-faced hammer (dead
action) to force it down onto the base of its
seat; then measure without delay.

e Caution:

Do not strike the seat of a Clean Bearing shaft, as
otherwise the bearing might no longer be correctly
seated on the locking ring.



a

Measure distance between measuring plate and
bearing collar on input shaft.
Enter all measurements in a table.
see page 23.28

RS230251

Key to abbreviations used in measurements:
MAb
= Dimension between measuring plate
and output shaft
MZw
= Dimension between measuring plate
and idler shaft
MAn
= Dimension between measuring plate
and input shaft
H
= Height of measuring plate
Overall dimensions:
GAb ....................................................... = H — MAb
GZw .......................................................= H — MZw
GAn ....................................................... = H — MAn

23.33

Clean Bearing

RT230261

Measuring gearbox cover
• Measure dimension between gearbox cover joint
face and base of bearing seat, taper roller bearing to bearing inner race.

Clean Bearing

e
Caution:
Always measure taper roller bearing with oil baffle

DAn
DZw

DAb

plate removed.
The oil baffle plate is slightly corrugated, which can
falsify the measurement.

RT230271

DAn
DZw

DAb

Key to abbreviations used in measurements:
DAb.......................= Cover dimension, output shaft
DZw ......................... = Cover dimension, idler shaft
DAn......................... = Cover dimension, input shaft


a

RS230270

23.34

Enter all measurements in a table
see page 23.28.

Shimming the gearbox shafts (without Clean Bearing)
Example

Dimensions in millimeters
H

Output shaft
"Ab"

Idler shaft
"Zw"

Input shaft
"An"

60,00 mm
(2.362 in)

60,00 mm
(2.362 in)

60,00 mm
(2.362 in)

0,05 – 0,15 mm
(0.00196...0.0059 in)

0,05 – 0,15 mm
(0.00196...0.0059 in)

M (measure!)

= G
D (measure!)

G

= clearance without spacers

specified end float

+ permitted preload

0,20 mm (0.00787 in)

= thickness of spacers

e
Caution:
To check friction coefficient of taper roller bearings
on input shaft, only install input shaft in
gearbox.
Bearings must be oiled.

Shimming the gearbox shafts (with Clean Bearing)
Example

Dimensions in millimeters
H

Output shaft
"Ab"

Idler shaft
"Zw"

Input shaft
"An"

60,00 mm
(2.362 in)

60,00 mm
(2.362 in)

60,00 mm
(2.362 in)

0,05 – 0,15 mm
(0.00196...0.0059 in)

0,05 – 0,15 mm
(0.00196...0.0059 in)

0,05 – 0,15 mm
(0.00196...0.0059 in)

M (measure!)

= G
D (measure!)

G

= Clearance without shims and
input-shaft bearing

specified end float

= Bearing (input shaft)
and shim thickness

23.35

Removing and installing taper roller
bearing race

Checking friction coefficient of input
shaft taper roller bearing

j

100

Install gearbox cover

X

Tightening torque:
Retaining screws.......................................... 10 Nm

00 8 562

00 2 570
00 8 561

RS230030


Gearbox cover temperature at bearing seat
100 °C.
Depending on tolerance, the bearing shell may
already slide out of its seat when the housing is
heated. If necessary, pull bearing race out with
Kukko counter-support, BMW No. 00 8 562, and
internal puller, BMW No. 00 8 561.
Remove spacing washers/oil baffle plate.

j

100

00 5 500

23 3 670
RS230291

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 second.

e

23 4 670
1

Caution:
To check friction coefficient of taper roller bearing
on input shaft, only install the input shaft in the gearbox.
Bearings must be oiled.

Friction value:
Preload 0.2 mm (0.00787 in) =
friction value 0.5 – 1.0 Nm

RS230032



Gearbox cover temperature at bearing seat
100 °C.
Place shims of the calculated thickness in the
gearbox cover/include the oil retaining plate (1).
Using drift, 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.

23.36

j

100

3

v
243

Clean Bearing

1

23 4 632
2

v
573

RT230281

Installing gearbox cover






Slightly grease the shims of the calculated thickness for the idler and output shafts (include oil
trap plate (1) in the shim thickness) and place
then flush on the deep-groove ball bearing.
Place sliding sleeve (2), BMW No. 23 4 632, on
the input shaft.
Apply a thin coat of Loctite 573 to the housing
joint face, which must be clean and free from
grease.
Heat the gearbox cover to 100 oC.
Fit gearbox cover/insert selector shaft and selector drum in bearings.
Preload arm of stop lever spring, attach and
completely fit gearbox cover.

X Tightening torque::

Retaining screws on gearbox cover ............ 10 Nm
Neutral detent screw
(clean thread + Loctite 243).......................... 13 Nm

e
Caution:
Arm of spring at clutch end of gearbox housing must
be under preload and must not be dis-placed towards the output end of housing.



Tighten down gearbox cover.
Insert idle stop (3) (ball and spring) into gearbox.
Insert the neutral detent screw with Loctite 243.

23.37

Removing and installing input shaft
seal at housing cover end

23 4 630

RS230290


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.

23.38

2

1

7
5
6
4
3
8

RS230300

Completing assembly of gearbox



Install retaining ring (1) in selector drum.
Install neutral switch (2).
If applicable, install gear display switch

e Caution:

Make sure that the O-ring is in good
condition.




Install clutch piston (3), coil spring (4)
and sleeve (5).
Attach hose clip (6).
Install clutch lever (7).
Install thrust rod (8).

X

Tightening 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:
API GL 5 SAE 90 ...................1.0 l (1.76 Imp. pints)

23.39

...... 23 1 820.... and push the gearbox carefully on to them. 22 Nm • Installation is performed in the reverse order to the removal procedure....Installing gearbox • Check centering of driving plate with centering pin.. BMW No......... 23... 21 3 680..... 23 1 820 23 1 820 RS230011 • Screw in guide pins (oiled). X Tightening torque: Gearbox to engine block ..40 . BMW No..

.16 ..................................................................................................................................................................................................................................11 Removing and installing ball joint ............................................................................................................................................................13 Dismantling telescopic fork ..9 Removing and installing ball thrust bearing .............................31 31 Front fork Contents Page Technical Data ..........14 Checking runout of fixed tube ... 3 Removing and installing telescopic fork ....................15 Removing and installing front suspension strut [R] Removing and installing steering damper ........................................................................................7 Removing and installing telescopic fork without fork bridge [RS] Removing and installing fork bridge .....................................................................................8 [GS/R/RT] Removing and installing fork bridge ...........................................................16 Checking the steering damper ...........................................................................................................10 Removing and installing slider tube bridge ................................................................................12 Dismantling/reassembling telescopic fork ....................................16 31................................................................................14 Measuring telescopic fork .....................................................................................................................16 Removing and installing ball head ...........................................................................................................................................................14 Removing and installing leading link .............................................11 [GS/R/RT] Checking ball joint/ball thrust bearing friction ................................................................................................................................................11 Assembly specification for telescopic fork: ........................................13 Assembling telescopic fork ....................................................................................................15 Dismantling/reassembling leading link ...................................................................1 .........7 .....11 [RS] Checking ball joint friction .......................................................................................................................................................14 Check slider tube bridge ..........................................................8 Removing and installing pot-type joints .........................................................................................................................................

2 .31.

425 lb)) Steering lock angle Total suspension travel mm (in) ° mm (in) Fixed tube surface 111 (4. pints) 0.3 .7244) Hard chrome plate Extl.827) Suspension strut Type Suspension strut with coil spring and twin-tube.31 Technical Data R 1100 RS Front suspension Type BMW Telelever with external suspension strut Telescopic fork Front wheel caster in normal-load position (with rider weighing 85 kg (187.3779) Maximum permissible runout of fixed fork tube mm (in) 0.4 (0.470 (0. gas-filled shock absorber 31.01574) Telescopic fork oil – approved grades Fill quantity in each fork leg BMW telescopic fork oil l (Imp. of fixed fork tubes mm (in) 35.37) 32 120 (4. dia.0 (1.

pints) 0. of fixed fork tubes mm (in) 35.Technical Data R 1100 RT Front suspension Type BMW Telelevr with external suspension strut Telescopic fork Front wheel caster in normal-load position (with rider weighing 85 kg (187.827) Suspension strut Type 31.4 (0.803) 34 120 (4.3779) Maximum permissible runout of fixed fork tube mm (in) 0.0 (1. gas-filled shock absorbe . dia.4 Suspension strut with coil spring and twin-tube.7244) Hard chrome plated Extl.425 lb)) Steering lock angle Total suspension travel mm (in) ° mm (in) Fixed tube surface 122 (4.470 (0.01574) Telescopic fork oil – approved grades Fill quantity in each fork leg BMW telescopic fork oi l (Imp.

dia. twin-tube.5275) ° 42 mm (in) 190 Hard chrome plated 115 (4.3779) Maximum permissible runout of fixed fork tube mm (in) 0.0 (1.4 (0.Technical Data R 850 GS R 1100 GS Front suspension Type BMW Telelever with external suspension strut Telescopic fork Front wheel caster in normal-load position (with rider weighing 85 kg (187.470 (0. of fixed fork tubes mm (in) 35.01574) Telescopic fork oil – approved grades Fill quantity in each fork leg BMW telescopic fork oil BMW telescopic fork oil l (Imp. gas-filled shock absorber 31.3779) 35.5 .01574) 0.470 (0.0 (1. pints) 0.425 lb)) Steering lock angle Total suspension travel Fixed tube surface mm (in) 115 (4.4 (0.5275) 42 190 Hard chrome plated Extl.827) 0.827) Suspension strut Type Suspension strut with 5 spring preload settings.

3779) Maximum permissible runout of fixed fork tube mm (in) 0.827) Suspension strut Type 31.01574) 0.01574) Telescopic fork oil – approved grades Fill quantity in each fork leg BMW telescopic fork oil BMW telescopic fork oil l (Imp.6 Suspension strut with twin-tube gas-filled shock absorber . dia.470 (0.4 (0.470 (0.4 (0.0 (1.7244) Hard chrome plated 127 (5) 37 120 (4.425 lb)) Steering lock angle Total suspension travel Fixed tube surface mm (in) 127 (5) ° 37 mm (in) 120 (4.0 (1. of fixed fork tubes mm (in) 35.3779) 35.827) 0.Technical Data R 850 R R 1100 R Front suspension Type BMW Telelever with external suspension strut Telescopic fork Front wheel caster in normal-load position (with rider weighing 85 kg (187.7244) Hard chrome plated Extl. pints) 0.

....... e Caution: To prevent grease from escaping and the ingress of dirt..... pull telescopic fork out downwards................... 31 5 600.......................... 9 Nm 31..............0..... 120 °C...... holding the hexagon on the fixed tube to prevent it from turning.................. • [ABS] Check sensor gap and adjust if necessary....................... [GS/R/RT] Slacken off the threaded connection for the fixed tube at the upper fork bridge....50............... fixed tube/fork bridge [RS] ..... 22 Nm Threaded connection........ GS000410 31 5 600 • • jw 120 • • v 2701 GS310021 • • Heat leading link mount at front to max.............. 20 Nm Steering damper mount at slider tube bridge (clean thread + Loctite 2701) [R] ............ 0.................... 130 Nm Mount........ [GS/R/RT] ... ensure that sleeve is correctly located on ball joint... Install in the reverse order of work.. [ABS] Detach sensor............0197....................... on leading link...........0217 in) X Tightening torque: Ball joint at leading link: (clean thread + Loctite 2701)..... Tighten ball joint at leading arm with socket wrench insert and internal hexagon.............0................ and take it of......7 ............................................ BMW No....55 mm . (0.......... 45 Nm Handlebar to fork bridge [R/RT] .......... [R/RT] Take off the handlebar. 21 Nm Steering damper at slider tube bridge mount (clean thread + Loctite 2701) [R] ..... fixed tube/fork bridge (free from oil or grease) ......................... ABS – Sensor gap: ....... Detach brake line retainer..... [R] Heat steering damper mount at slider tube bridge to max....................... [RS] Loosen fixed-tube clamp at upper fork bridge and pull telescopic fork out downwards.......... Remove front wheel..Removing and installing telescopic fork Removing and installing telescopic fork without fork bridge • • • • • Remove mudguard............. 120 °C and unscrew.......

L Note: Screw pin is a press fit in ball thrust bearing: remove complete unit.... Remove fork bridge........... Unfasten screw connection between fork bridge and frame.......... Remove ignition/steering lock... 130 Nm • • Unfasten fixed tube screw connection at fork bridge....... 120 1 31 5 600 GS310030 GS000410 • • • • • • Remove trim (1)........ • • • • [R] Scheinwerferhalterung nach vorne ziehen........ 45 Nm Handlebar to fork bridge ..... 31 5 600... 120 °C and unscrew using Allen key socket wrench insert............. Zündlenkschloß ausbauen......... 130 Nm Threaded connection between fork bridge and fixed tube (free from oil and grease).. Install in the reverse order of work... Heat ball joint mount on fork bridge to max...... Detach handlebar from fork bridge........ 22 Nm Ball joint at fork bridge (clean thread + Loctite 2701).. preventing movement by holding hexagon on fixed tube..... Unscrew fixed tube clamp mount at top of fork bridge. 5 ± 0. Gabelbrücke abnehmen........ fixed tube/fork bridge .....5 mm (0.. 21 Nm 31........[RS] Removing and installing fork bridge [GS/R/RT] Removing and installing fork bridge • • • • Separate connecting plug for ignition/steering lock.. • jw Unscrew fuel tank and pull to the rear...... Einbau in umgekehrter Reihenfolge... X Tightening torque: Screw connection between fork bridge and frame (clean thread + Loctite 243). Projection of fixed tube beyond fork bridge: ........1969± 0... BMW No......... Unscrew handlebar mount on fork bridge....01969 in) X Tightening torque: Mount.........8 .. Separate connecting plug for ignition/steering lock..

Install snap ring (2). 31 5 661. 31 5 660.9 .Removing and installing pot-type joints 31 5 661 1 2 1 31 5 662 GS310080 • • • Remove dust covers (1). Press in pot-type joint using drift. Install dust covers (1). 31. Remove top snap ring (2). Press out pot-type joint using drift and bushing. 31 5 661 1 2 1 3 GS310090 • • • • Snap ring (3) is installed. BMW No. BMW No.

Removing and installing ball thrust bearing jw 100 31 5 651 jw 100 1 31 5 653 GS310130 GS310100 • • • • Remove retaining ring (1). Install retaining ring. 31 5 651 and bushing. as a support. if necessary striking lightly with a plastic-faced hammer. Heat fork bridge to 100 °C. BMW No. BMW No. Remove ball thrust bearing. BMW No. 31 5 651. .10 • Heat the fork bridge to 100 °C and press the ball thrust bearing in with pin. BMW No. 31 5 651 GS310120 • Press the threaded journal into the ball thrust bearing using a pin. 31 5 651 GS310110 • Press out the threaded journal using a pin. 31. as a support. 31 5 653. 31 5 651.

Removing and installing slider tube
bridge



Remove front mudguard.
Heat ball joint mount at slider tube bridge to max.
120 °C and detach it.
[R] Heat the steering damper mount at the slider
tube bridge to max. 120 °C and detach it..

[RS] Checking ball joint friction
[GS/R/RT] Checking ball joint/ball
thrust bearing friction


v
243

v

Motorcycle must be supported on center stand
with front wheel clear of the ground.
Measure the breakaway torque to left and right
from the central position of the handlebar with
friction gauge, BMW No. 00 2 57.

2701

jw

120

L Note:

To determine the friction value, increase torque very
slowly.

Friction value:
Measure at room temperature (above 20 °C)
Nominal value: .................................... 1.0...4.0 Nm

GS310040





[RS/GS] Detach the brake line distributor block.
[ABS] Detach the sensor line from the slider tube
bridge.
Unscrew slider tube bridge.
Install in the reverse order of work.
Secure the ball joint to the leading link using
socket wrench insert and Allen key,
BMW No. 31 5 600.

e Caution:

Comply with assembly instructions for telescopic
fork.

X

Tightening torque:
Bridge to fork slider
(clean 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.

X

Tightening torque:
Ball joint to fork slider bridge ...................... 230 Nm

31.11

Assembly specification for telescopic fork:

e
Caution:
To ensure that the fork is installed without trapped

stresses, observe the following instructions and the
specified working sequence precisely.

Tightening torque:
Leading link at ball joint
(clean thread + Loctite 2701)...................... 130 Nm

X

The front suspension strut is removed.

e Caution:

Protect painted parts from scratching: apply adhesive masking tape if necessary.

Secure slider tube bridge/do not tighten to specified torque at this point.
Screw slider tube bridge to leading link.

Bolt fork bridge to frame.

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.

X

X Tightening torque:

Fork bridge to ball joint
(clean thread + Loctite 2701)
[RS] .......................................................... 130 Nm
Threaded journal to frame
(clean thread + Loctite 243)
[GS/R/RT] ................................................. 130 Nm

Tightening torque:
Clamp between fixed tubes and fork bridge
[RS] ............................................................. 22 Nm
Screw connection between fixed tube and fork
bridge (oil/grease free)
[GS/R/RT].................................................... 45 Nm

Tighten down slider tube bridge.

X

Tightening torque:
Bridge to fork slider (clean thread +
Loctite 243) .................................................. 22 Nm

A

Check that the system moves freely by compressing and extending the suspension (but
without the suspension strut) in the straightahead and left/right steering lock positions.
Remove quick-release axle.

e

GS310140

Pre-assemble fork legs with quick-release axle/
adjust distance A.

Distance A:.............165

± 0.5

mm (6.496± 0.01969 in)

X
Tightening torque::
Quick-release axle clamps ........................... 22 Nm
L Note:

If the quick-release axle was not removed, for instance when only the fork slider tube bridge was removed/installed, the above work stage is omitted.

31.12

Caution:
When being reassembled, the quick-release axle
must well aligned; it should be possible to install it
by rotating it slightly.

Install suspension strut.

X

Tightening torque::
Spring strut to frame .................................... 47
Spring strut to leading link
[RS] (8.8 bolt)............................................... 43
[RS] (10.9 bolt)............................................. 50
[GS/R/RT] (10.9 bolt) ................................... 50

Nm
Nm
Nm
Nm

GS/R/RT

1

1

RS

3
4
5
6
7
2
GS310050

Dismantling/reassembling
telescopic fork
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)

e Caution:

Do not damage fork slider tube.

Remove washer (6).

31.13

Assembling telescopic fork

Measuring telescopic fork

Insert oil drain plug.

e
Caution:
Install a new O-ring (7). Make sure the O-ring is cor-

e

Caution:
After an accident, always examine the telescopic
fork for cracks and signs of damage.

rectly seated.

Fill with oil.

Fill quantity per fixed tube:
[RS/GS/R/RT] .................0.470 l (0.827 Imp. pints)
Oil grade in telescopic fork:
..........................................BMW telescopic fork oil

L Note:

Check slider tube bridge
• Check that the slider tube bridge is flat.

e Caution:

Renew slider tube bridge if distorted.

Checking runout of fixed tube

No oil changes required during services: unit is
maintenance-free.






Install fixed tube.
Install washer (6).
Oil the shaft seal slightly and push it on as far as
possible (to stop on slider tube) by striking it
lightly with drift, BMW No. 31 5 610, and reducing adapter, BMW No. 31 5 613.
Install retaining ring and dust cover.
Insert bleed screw (1).
Bleed telescopic fork in no-load position.

X Tightening torque:

[RS] Threaded plug at fixed tube ................. 18 Nm
[GS/R/RT] Threaded plug at fixed tube
....................................... press-fit - do not remove!

RS310061


Place both ends of fixed tube in V-blocks.
Rotate fixed tube slowly and check with dial
gauge while doing so.

e

Caution:
Do not straighten distorted fixed tubes:
always renew them.

Permissible runout: ................. 0.4 mm (0.0157 in)

31.14

31 5 600

2
3
1
7

jw

120

6

5
4
2

v
2701

RS310010

Removing and installing leading link

X
Tightening torque:
Right control arm on engine ......................... 73 Nm


Left screw cap (coat thread lightly with
Never Seez).................................................. 42
Leading link to ball joint
(clean thread + Loctite 2701)...................... 130
Spring strut to leading link
[RS] (8.8 bolt)............................................... 43
[RS] (10.9 bolt)............................................. 50
[GS/R/RT] (10.9 bolt) ................................... 50
Steering damper mount to leading link
[R]................................................................ 20







[RT] Remove side sections of fairing.
[R] Detach steering damper mount at leading
link.
Unscrew bottom of spring strut.
Heat ball joint mount (1) at leading link to max.
120 °C and detach it.
Remove covers (2) from leading link pivots.
Remove left screw cap (3).
Remove right retaining ring (4) and retaining
cap (5).
Take out right screw (6) and remove shaft (7) by
pulling to the left.
Pull telescopic fork forwards and carefully remove leading link by pulling forwards.

e Caution:

Protect painted parts from scratching: apply
adhesive masking tape if necessary




Install 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.

Nm
Nm
Nm
Nm
Nm
Nm

Dismantling/reassembling leading
link

Press bearing out/in using suitable tool.

e
Caution:
Always install bearing by applying pressure to
outer race.

L
Note:
Only applies to plain bearings
31.15

Removing and installing front
suspension strut

Removing and installing ball head


[RS] Coat lower suspension strut pivot with
Never Seeze.

Unscrew ball head.
When installing, locknut must make contact with
piston rod/end of thread; lock ball head against
nut.

L
Note:
Only applies to plain bearings.

e
Caution:
Do not dismantle the steering damper.

X Tightening torque:

Tightening torque:
Steering damper at slider tube bridge mount
(clean thread + Loctite 2701)........................ 20
Steering damper mount at slider tube bridge
(clean thread + Loctite 2701).......................... 9
Steering damper at leading link mount
(clean thread + Loctite 2701)........................ 20
Steering damper mount to leading link ......... 20
Joint head to locknut.................................... 20

X

Spring strut to frame .................................... 47
Spring strut to leading link
[RS] (8.8 bolt) ............................................... 43
[RS] (10.9 bolt) ............................................. 50
[GS/R/RT] (10.9 bolt) ................................... 50

Nm
Nm
Nm
Nm

[R] Removing and installing steering
damper

Nm
Nm
Nm
Nm
Nm

Checking the steering damper



v
2701

jw

120

v
2701

jw

120

jw

120

v
2701

RS310150

Heat steering damper mount to max. 120 °C and
detach it.

31.16

Freedom from play at ball head.
Freedom from play at piston rod.
Turn the steering to the left and try to rock the
front end of the housing radially to and fro.

32

32 Steering

Contents

Page

Technical Data ............................................................................................................................... 3
Removing and installing left handlebar fitting

.............................................................7
With heated handlebar grips ................................................................................................................7
Without heated handlebar grips ...........................................................................................................7

Removing and installing right handlebar fitting

..........................................................8
With heated 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

32.1

32.2

32

Technical Data
Steering lock angle

R 1100 RS
°

2 x 32

Steering head tube dia.

mm (in)

22 (0.866)

Handlebar width with weights

mm (in)

738 (29.055)

32.3

866) Handlebar width with weights mm (in) 775 (30.4 . mm (in) 22 (0.Technical Data Steering lock angle R 1100 RT ° 2 x 34 Steering head tube dia.512) 32.

Technical Data Steering lock angle R 850 GS ° 2 x 42 R 1100 GS 2 x 42 Steering head tube dia.866) 22 (0.5 .0397) 890 (35.0397) 32.866) Handlebar width with weights mm (in) 890 (35. mm (in) 22 (0.

mm (in) 22 (0.866) 22 (0.Technical Data Steering lock angle R 850 R ° 2 x 37 R 1100 R 2 x 37 Steering head tube dia.6 .7087) 32.866) Handlebar width with weights mm (in) 780 (30.7087) 780 (30.

Without heated handlebar grips • Cut through rubber grip and pull it off. Separate plug connection (1) at clutch switch. a See Group 00 With heated handlebar grips Fold back rubber grip at handlebar fitting end. Unfasten retaining screws for heated handlebar grip. a See Group 00 • Check/adjust raised idle speed (choke) setting.GS/R/RT RS 1 4 3 2 4 GS320010 Removing and installing left handlebar fitting • • • • • • • • [RS] Remove left side fairing. • Unfasten cable shoes at connector. • Secure handlebar grip with Loctite 638 adhe-sive and surface activator. • Pull lead through handlebar. Disconnect cable for raised idle speed (choke) at actuating lever (2). • Adjust clutch cable and lubricate pivot with Shell Retinax A. Unfasten screw (3) and pull out handlebar weight. • Remove fitting from handlebar. then from handlebar lever.7 . [RT] Remove upper section of fairing. • Align slot of handlebar fitting (arrow) with punchmark on handlebar. Disconnect clutch cable from release lever. Remove combination switch. • Loosen clamp screw (4) on handlebar fitting. • Separate connector to heated handlebar grip. • • 32. • Install in the reverse order of work. [GS/R] Detach fuel tank and pull to the rear.

... Separate connector (1) at brake light switch. Without heated handlebar grips • Cut open rubber grip (4) and pull off....... bleed brake system. [GS/R] Detach fuel tank and pull it to the rear.. If necessary.. Unfasten screw (3) and pull out handlebar weight. • Remove handlebar fitting. 7 Nm ....... • Install in the reverse order of work.... • Separate connector to heated handlebar grip. painted parts of the motorcycle.. • Secure rubber handlebar grip with Loctite 638 adhesive and surface activator. [RT] Remove upper section of fairing.3937in)) from the center section of the handlebar.. 10 mm (0..1969.. 32.... X Tightening torque: Brake hose to fitting . 5 . unfasten the wiring harness.0. e Caution: e Caution: Do not allow brake fluid to come into contact with Top up brake fluid... With heated handlebar grips • Fold back rubber grip at handlebar fitting end. because brake fluid destroys paint. • • • Remove combination switch.. • Unfasten retaining screws for heated handlebar grip. Detach brake line and seal off. Unfasten throttle cable cover (2) and disconnect throttle cable...8 – Adjustable handlebar – In the center position the brake hose fitting at the master brake cylinder must have sufficient clearance (app.... • Pull lead through handlebar. • Unfasten cable shoes at connector... • Unfasten clamp screw (5) from fitting housing.... • Align slot of handlebar fitting (arrow) with punchmark on handlebar...GS/R/RT RS 2 3 4 5 1 GS320020 Removing and installing right handlebar fitting • • • • • [RS] Remove left side trim.

1 RS320030 [RS] Removing and installing handlebar • • • • Remove left/right handlebar fittings... 40 Nm Rubber mount at fork bridge ......... X Tightening torquet: Handlebar at rubber mount ...... e Caution: Ensure that brake hoses are correctly located.............9 ............... Install in the reverse order of work............... 40 Nm Handlebar weight to fixed handlebar ....... 7 Nm 32.... Remove handlebar.. 20 Nm Handlebar weight to adjustable handlebar (clean thread + Loctite 2701)......... Remove trim (1) from fork bridge (press hooks in direction of arrow)...........

........ 21 Nm Handlebar to fork bridge [R/RT]... e Caution: Make sure that brake hoses are correctly routed............ Remove handlebar......................................... X Tightening torque:: Clamp to fork bridge [GS] ........ Install in the reverse order of work...... 20 Nm 32...................GS R/RT GS320030 [GS/R/RT] Removing and installing handlebar • • • Remove left/right handlebar fittings.............................. [GS] Align punch mark on handlebar with gap between clamp blocks......10 .... 21 Nm Weight to handlebar ..........................

See Group 00 32. Remove the cable cover at the throttle operating fitting. Pull the wire cable distributor block (2) out of holder (3) in the direction of the arrow. Detach the wire cables at the left and right throttle stub pipes.11 . Detach the engine breather pipe (1) from the engine. Unscrew fuel tank and pull to the rear. Install in the reverse order of work. Adjust the wire cables.1 2 3 RT320120 Removing and installing wire cable distributor block • • • • • • • • • • a [RS/RT] Remove side fairings. Remove cold-start lever (increased idle speed)/ disconnect the wire cable. Relesse the cable straps.

32.Removing and installing throttle cable • • 4 4 [RS] Remove left side fairing. [GS/RT] Detach fuel tank and pull it to the rear. 2 3 GS320110 • • Unfasten cable adjusting screw (2) on the right throttle body. 5 RS320050 1 • • RS320041 • Remove cable cover (1) from handlebar fitting and disconnect cable. • 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. See Group 00 . Press in retaining spring (3) and disconnect cable. e Caution: Install wire cable without kinking.12 • a Adjust wire cable.

Install in the reverse order of work. Disconnect cables (9). Adjust the wire cables. • Remove the choke lever/disconnect the cable. • Press in retaining spring (3) and disconnect the cables. (10) and (11). Release the keeper (7) and remove the distributing disk (8).13 .With wire cable distribution block • Remove cable cover (1) at fitting/disconnect the cable. 7 10 11 8 9 6 • • • • • a RT320130 Pull out the cable distribution block (6) in the direction of the arrow. • Remove the wire cable adjusting screws (2) at the right and left throttle stub pipes. See Group 00 32.

• Remove the cable adjusting screws at the right and left throttle stub pipes. • a Adjust wire cable.. e Caution: Install wire cable without kinking. • Press in the retaining spring and remove the cable 1 RS320060 • 5 4 Remove actuating lever (1)/disconnect cable • • • • 2 a 3 RS320070 • • • Slacken off cable adjustment screw (2) on left throttle body Press in retaining spring (3) and disconnect cable. • Remove actuating lever (1)/disconnect cable.14 RT320130 Remove the wire cable distribution block (4) in the direction of the arrow. [GS] Detach the fuel tank and pull it to the rear. See Group 00 32.Removing and installing cold-start cable • • [RS/RT] Remove the left fairing. Detach cable (5). Install in the reverse order of work. Adjust wire cable See Group 00 . Install in the reverse order of work. With wire cable distribution block • Remove cable cover at throttle fitting/disconnect the cable.

15 . RS320081 • Disconnect clutch cable from release lever/gearbox. e Caution: Install wire cable without kinking. [RT] Detach fuel tank and pull it to the rear. See Group 00 32. Install in the reverse order of work. • a Adjust wire cable. RS320091 • • Disconnect clutch cable from handlebar lever.Removing and installing clutch cable • • Remove right side trim.

...............................................................................................................24 Removing drive shaft ....................19 ................................13 ..................................................................................20 ......................20 Installing rear wheel drive ................17 Checking/adjusting backlash ................................................................................................................. reassembling and installing rear swinging arm Removing rear swinging arm .......................................26 33...................................................................................................................................23 ............................................................14 Removing and installing taper roller bearing in rear wheel drive Removing crown wheel Installing crown wheel ........................................... 3 Rear wheel drive-sectioned drawing ........................12 Assembling input bevel pinion Installing input bevel pinion .................................24 Installing drive shaft ...........................................................................7 Removing.....................................9 Disassembling input bevel pinion ................................................................................................25 Removing and installing suspension strut ..................................................................................16 .........................................................................................................................................................................21 Removing.............................................................................................................................................................................................................................................9 Removing input bevel pinion .... dismantling........................11 Removing needle roller bearing for input bevel pinion ..............15 .............................................................................................................................................................................................................................................................................24 Installing rear swinging arm ....................23 Removing and installing taper roller bearing Removing and installing flexible gaiter .............................................. dismantling....................................................................................20 Installing splined element .12 Installing needle roller bearing for input bevel pinion ...............................................................................................................................................23 .........18 Checking tooth contact pattern Shimming housing cover Installing housing cover .......................................................................................................................1 .9 ..................................................................................................... reassembling and installing rear wheel drive Removing rear wheel drive .................................33 Rear wheel drive 33 Contents Page Technical Data ...........24 Checking universal joint for wear .......................................................................................................................................................................................

33.2 .

SAE 90 GL 5 Filling capacity Initial filling l(Imp.07.315) 33.0. mm (in) 135 (5.1 (0. seven spring preload settings.. continuously variable rebound-stage damping. pints) 0.05..33 Technical Data R 1100 RS Rear wheel drive Gear tooth pattern Klingelnberg-Palloid spiral bevel Gear ratios up to 1993 model year 3.405) Drive shaft Layout Two-piece drive shaft with integral torsional vibration damper enclosed in single swinging arm (BMW PARALEVER).. universal joints at both ends.00276.81 : 1 Number of teeth 31 : 11 Backlash mm (in) 0.0063) Taper roller bearing preload mm (in) 0.976) Rear suspension Suspension strut Suspension travel Suspension strut with single-tube.03937) Oil grades Brand-name hypoid gear oil. pints) 0.0.3 .23 (0.... Swinging arm Swinging arm length mm (in) 355 (13.00197..16 (0.09 : 1 Number of teeth 34 : 11 from 1994 model year on 2.44) Oil changes l(Imp.. gas-filled shock absorber.25 (0.0.0. sliding joint at rear wheel drive end.

0063) Taper roller bearing preload mm (in) 0.23 (0..00276..16 (0.0. pints) 0.Technical Data R 1100 RT Rear wheel drive Gear tooth pattern Klingelnberg-Palloid spiral bevel Gear ratios 2.05.315) .. Swinging arm Swinging arm length mm (in) 355 (13.0.91 : 1 Number of teeth 32 : 11 Number of teeth Backlash mm (in) 0.. mm (in) 135 (5..405) Drive shaft Layout Two-piece drive shaft with integral torsional vibration damper enclosed in single swinging arm (BMW PARALEVER). sliding joint at rear wheel drive end.44) Oil changes l (Imp. pints) 0.4 Suspension strut with single-tube gas-filled shock absorber. continuously variable rebound-stage damping and continuous hydraulic spring preload.00197.07.1 (0... universal joints at both ends.0.25 (0.976) Rear suspension Suspension strut Suspension travel 33.03937) Oil grades Brand-name hypoid gear oil. SAE 90 GL 5 Filling capacity Initial filling l (Imp.0..

.36 : 1 Number of teeth 37 : 11 3..00276.5 ..0.16 (0.44) 0.25 (0..Technical Data R 850 GS R 1100 GS Rear wheel drive Gear tooth pattern Klingelnberg-Palloid spiral bevel Gear ratios 3. continuously variable rebound-stage damping and continuous hydraulic spring preload.0. pints) 0..874) 33.0. pints) 0..03937) Oil grades Brand-name hypoid gear oil.00276.07.0. 200 (7.00197.976) Rear suspension Suspension strut Suspension travel Suspension strut with single-tube gas-filled shock absorber.07.03937) 0.25 (0.05. SAE 90 GL 5 Filling capacity Initial filling Initial filling l (Imp..405) 0..44) Oil changes Oil changes l (Imp.0. mm (in) 200 (7... continuously variable rebound-stage damping and continuous hydraulic spring preload.1 (0...1 (0. sliding joint at rear wheel drive end. Swinging arm Swinging arm length mm (in) 355 (13. universal joints at both ends.00 : 1 33 : 11 Backlash mm (in) 0.0.0..405) Drive shaft Layout Two-piece drive shaft with integral torsional vibration damper enclosed in single swinging arm (BMW PARALEVER)..23 (0.0.23 (0.0063) 0.16 (0.05...0063) Taper roller bearing preload mm (in) 0.976) 355 (13.00197.874) Suspension strut with single-tube gas-filled shock absorber.

0063) Taper roller bearing preload mm (in) 0..0.0.25 (0.315) Suspension strut with single-tube gas-filled shock absorber.0..07..44) Oil changes Oil changes l (Imp.05.315) ...Technical Data R 850 R R 1100 R Rear wheel drive Gear tooth pattern Klingelnberg-Palloid spiral bevel Gear ratios 3.405) Drive shaft Layout Two-piece drive shaft with integral torsional vibration damper enclosed in single swinging arm (BMW PARALEVER).. SAE 90 GL 5 Filling capacity Initial filling Initial filling l (Imp. mm (in) 135 (5.0.03937) Oil grades Brand-name hypoid gear oil.976) Rear suspension Suspension strut Suspension travel 33. 135 (5. universal joints at both ends.23 (0...05.44) 0.1 (0.1 (0.00276.36 : 1 Number of teeth 37 : 11 3.00276.0.16 (0.23 (0. pints) 0..00197.16 (0. sliding joint at rear wheel drive end. continuously variable rebound-stage damping and seven-position adjustable spring preload.0. Swinging arm Swinging arm length mm (in) 355 (13..0. continuously variable rebound-stage damping and seven-position adjustable spring preload..25 (0.00 : 1 33 : 11 Backlash mm (in) 0.07. pints) 0..03937) 0.0.976) 355 (13.0063) 0....6 Suspension strut with single-tube gas-filled shock absorber.405) 0.00197..

7 .Rear wheel drive-sectioned drawing RS339011 33.

8 .33.

[GS] Remove rear wheel cover at rear wheel drive. If necessary. Release clamping strap (2). Unfasten brake caliper/secure to rear frame with cable strap. remove/install circlip. L Note: If rear wheel drive is filled with oil. Loosen strut at rear wheel drive (1). Remove free bearing/fixed bearing journal (3/4). L Note: Inner races of needle bearings.9 . 120 °C/loosen. do not place on side prior to installation: this will cause oil to escape later. when the bike is ridden (suction effect). [RS] Remove number plate carrier. Heat free bearing journal (3) to max. [ABS]/[GS/R/RT] Remove sensor. • • Detach strut from rear wheel drive. 120 °C/ loosen. with [ABS] mark position before removing. dismantling. heat fixed bearing journal (4) to max. LT 33.j 120 3 4 1 2 j 120 RS330010 Removing. Disconnect rear wheel drive from drive shaft. reassembling and installing rear wheel drive • • • • • Drain the oil. [RS/R/RT] Remove brake disk/heat retaining bolts to 120 °C. 33.043 LT330430 • • Press out splined section of shaft. Removing input bevel pinion Removing rear wheel drive • • • • • • Remove rear wheel.

Heat housing to 120 °C and unscrew threaded ring (7) with pin wrench (2).j j 100 120 7 6 5 8 LT330012 5 33 1 720 1 2 33 1 510 1 33 1 700 1 4 3 2 RT330350 • • • • • Bolt rear wheel drive centrally onto retaining fixture. Tighten with wheel studs (2). Bolt the locking arm (3) on tight. 33 1 700. 33 1 510. 33 1 720 Remove thrust ring (6). Tighten grub screws (4) until they make contact. BMW No. with bearing journal (1).10 Heat hex nut (5) at input bevel pinion to 100 °C and unscrew it with 36 mm socket wrench insert and reducing adapter (1). Move threaded sockets (5) up to rear wheel drive. To remove the input bevel pinion (8). heat bearing seat to 120 °C. . RT330360 • e Caution: Never use a hammer when loosening the hex nut: this could damage the splines. • • • 33. BMW No. BMW No.

inner race (10). BMW No.12 8 11 10 9 7 6 LT330030 Disassembling input bevel pinion • • • Remove outer bearing race (7). roller bearing cage (11) and outer race (12) 33. Remove spacer ring (8) from housing.11 . pull off both bearings at the same time. Clamp input bevel pinion (6) into vise with protective jaws (splines facing upwards). 00 7 500. 00 7 500 LT330040 • • Using puller. Take off ball thrust bearing (9).

Heat the housing to 130 °C. 00 8 570 00 8 573 LT 33. 33. BMW No.Removing needle roller bearing for input bevel pinion LT330020 • • Split the needle roller bearing cage open. 00 8 573. 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 input bevel pinion..12 .006 RT330060 • Pull out the needle roller bearing outer race with internal puller. 00 8 570. BMW No. and countersupport.

j 100 12 11 10 9 6 LT330071 Assembling input bevel pinion • • • • Heat the inner race (10) to 100 °C and push onto input bevel pinion (6) as far as the stop. Allow input bevel pinion to cool down. 33. Slide outer race (12) together with roller cage (11) onto inner race (10).13 . Heat ball thrust bearing (9) to 100 °C and push onto input bevel pinion (6) as far as the stop.

118 Nm Nut for input bevel pinion (thread cleaned + Loctite 273).... e Caution: Nut must not damage shaft sealing ring..... • 00 5 500 Tighten hex nut (3).... Heat the housing to 120 °C.. Insert outer race (7)..... and handle. 33 1 760 X 13 5 LT330090 • • • • • • • Drive sealing ring (13) into threaded ring (5) with drift. 33. using Loctite 273. BMW No.. 33 1 700. 00 5 550.. BMW No... 33 1 760.. Install thrust ring (4).7 8 j 100 v 273 13 5 4 3 LT330080 L Note: Installing input bevel pinion Ensure that lip of shaft seal is perfectly aligned on thrust ring..... 200 Nm . BMW No.. Install input bevel pinion together with spacer disc (8). Coat threaded ring (5) with Hylomar SQ 32 M.14 Tightening torque: Threaded ring (thread cleaned + Hylomar SQ 32 M) . Tighten threaded ring with pin wrench..

Heat neck of housing to 120 °C. 33. Press in needle roller bearing with inner race on drift. BMW No.Removing and installing taper roller bearing in rear wheel drive 00 8 573 00 8 572 • • • RT330090 Pull out needle roller bearing using countersupport 22/1. BMW No. 00 8 572.15 . BMW No. and internal puller 21/4. 36 3 700. 00 8 573.

Insert pressure block. Using puller.16 33 1 307 LT330130 • • • Clamp crown wheel in vise with protective jaws.j 100 3 2 1 4 LT330111 Removing crown wheel 33 1 830 RT330121 • • • Remove housing cover (1) with crown wheel (2) and bearing (3).. 33. . 33 1 307 (arrow). Force shaft seal (4) out of housing cover with drift. BMW No. Heat housing cover to 100 °C and pull it off. pull off the deep-groove ball bearing. BMW No. 33 1 830.

L Note: If new parts are installed (e. 00 7 500. BMW No.g. pull taper roller bearing off crown wheel. taper roller bearing). BMW No. Install crown wheel (3). Heat deep-groove ball bearing (4) to 80 °C and place it in position. BMW No. Insert the outer race in the bearing seat with drift. 33 1 880. and handle. BMW No.Installing crown wheel 00 5 500 00 7 500 33 1 880 LT330140 • Using puller. 33. 4 LT330150 • Pull out the outer race using internal puller. Heat taper roller bearing (2) to 80 °C and push it on. 00 5 500.17 . 3 1 2 RT330170 • • • • Place the existing spacer ring (1) on the crown wheel. LT330160 • • 00 8 560 • Heat the housing to 80 °C. 00 8 560. check tooth backlash and adjust if necessary. Check that outer race is correctly fitted by striking gently.

. 33 2 604...................07.. 33...0063 in) ... Attach measuring arm (3). (0... BMW No.........18 • Compensate for excessive backlash by inserting a thinner shim washer..0..Checking/adjusting backlash 33 2 604 3 2 33 2 600 1 1 RT330210 RT330190 • • Place measuring fixture (1). Backlash: (adjusting without oil).......... press the crown wheel into the housing and turn to and fro to check tooth backlash.. BMW No.. with dial gauge on the crown wheel and secure to housing with knurled screw (2).0.... centrally to crown wheel 90° RT330200 • With the palm of the hand... and for insufficient backlash by inserting a thicker shim washer (1)... turn the bevel pinion with the crown wheel....16 mm .........00276...... L Note: Check tooth backlast at three points 120 degrees apart. 33 2 600. 0..

a thicker shim washer must be installed. R LT330230 • If the correct spacer disc is installed. Insert the crown wheel. a thinner shim washer must be installed. housing or input bevel pinion bearing have been renewed 1 LT330240 • If this contact pattern is obtained. press into housing with the palms of the hands and turn to and fro.Checking tooth contact pattern • The tooth contact pattern must be checked if the gear set. The contact point is closer to the larger diameter on back flank R. e Caution: Teeth should never make contact at the smaller diameter. LT330250 • V If this contact pattern is obtained. • • Degrease the tooth flanks on crown wheel and pinion.19 . 33. LT330220 L Note: The contact pattern is adjusted at the shim washer (1) on the input bevel pinion. the following contact pattern appears when no load is applied. and coat with engineer’s blue. L Note: The contact point is central on front flank V.

.. BMW No....0.... BMW No. and handle. in position and secure. 35 Nm Installing splined element 33 2 601 • b • • LT330270 • • • • Place measuring ring.. 00 5 500......... 33 1 860...1 mm (0. Heat housing cover to 80 °C/install..... Install O-ring and apply a light coat of oil/grease..0. the housing cover must be shimmed 00 5 500 00 2 550 33 1 860 a LT330280 • LT330260 • Using depth gauge. Tighten retaining bolts in a crosswise pattern X Tightening torque: Housing cover. BMW No..00197. Apply a light coat of grease to the selected shim washer. Fit sliding element to drive pinion. Locate retaining ring with gentle blows (plastic hammer)..... measure distance a..05.... . 33 2 601. Preload:.Shimming housing cover • Installing housing cover To obtain the correct roller bearing preload.......... 0.. Distance a – distance b = shim thickness (without preload).. and install it.. drive in the sealing ring.. Measure from the outer ball bearing race through the cutout in the measuring ring to the housing joint face and determine distance b.03937in) 33.. 00 2 550.20 Coat splines on input pinion with Staburags NBU 30 PTM.. BMW No.......... • • • • Using drift.

. The Loctite hardening time is at least 3 hours.... Tighten idler bearing for swinging arm............. 70636-AC the needles.... L Note: Use an acetone-based cleaning agent............. • Screw in fixed bearing journal (3) using Loctite.... and screw it in. 105 Nm 33.....v 2701 4 1 2 3 5 6 v 2701 LT330011 Installing rear wheel drive • • • Coat splines at sliding element (arrow) with Staburags NBU 30 PTM. (thread cleaned + Loctite 2701 applied to complete löength of thread on free bearing pin).... e.. e Caution: The inner race must never press against the ends of Loctite Rapid Cleanser 706 Loctite Order No........ 7 Nm Locknut......g.... Tighten fixed bearing of swinging arm.21 ..... • • X Tightening torque: Free bearing journal • Apply Loctite to the entire length of the thread on free bearing pin (4).. Apply a small amount of grease to the inner race (1............ e Caution: X Tightening torque: Fixed bearing journal (thread cleaned + Loctite 2701). 2) of the left needle roller bearing and install it.. 150 Nm e Caution: When threaded connections are made with the aid of Loctite 2701. Install rear wheel drive with gaiter..... Support the rear wheel drive.. insert sliding section into drive shaft.... they must be tightened to their final torque without delay.

........0.....0.. Install brake caliper....45....44 Imp.........• Apply a weight of approx......22 . API class GL 5 • • • [ABS]/[RS/R/RT] Install the brake disc in the previously marked position.. 85 kg to the motorcycle and tighten the strut (5) previously loosened..... pints) Oil grade: Brand-name hypoid gear oil...... Install the rear wheel...........0177. Fill quantity: Initial filling......... [GS] Install the rear wheel cover. do not tilt when installing.....23 l (0........... • • [GS/R/RT]/[ABS] Install the sensor.....405 Imp. e Caution: Do not damage brake pads...0............. If necessary.. SAE 90... [ABS] Check that sensor gap is correct. 43 Nm • • Tighten clamping strap (6) on gaiter.. pints) During oil changes .....02165 in) • • [RS] Install the number plate holder. (0....... ABS rear sensor gap: .55 mm .25 l (0.. fill with oil..0.. 33.0........ X Tightening torque: Reaction link to rear wheel drive..........

reassembling and installing rear swinging arm Removing and installing taper roller bearing Removing rear swinging arm • • • • • • • Unfasten suspension strut mount (1). BMW No. [RT] Detach brake master cylinder from right footrest plate. Pull out outer race with internal puller 21/5. 00 8 572. Unfasten free swinging arm bearing 00 8 572 00 8 571 00 8 563 LT330370 • • • Using counter-support. [RT] Detach gear shift linkage from left footrest plate. To install the bearing. 120 °C/loosen. 00 8 563.3 j 120 2 1 j 120 RS330031 Removing. [RT] Remove right and left footrest plates. BMW No. dismantling. Heat fixed swinging arm bearing (3) to max. pull out taper roller bearing. 00 8 571. heat the swinging arm to 80 °C. 120 °C/unscrew.23 . BMW No. and internal puller 21/2. 33. Heat free swinging arm bearing (2) to max.

. use a rubber mat. coat inner and outer sealing lips (arrows) with Staburags NBU 30 PTM.Removing and installing flexible gaiter Checking universal joint for wear LT330420 LT330300 • • Remove inner retaining ring. Fit drive shaft to output shaft. e Caution: Do not scratch painted components: if necessary. Removing drive shaft RS330040 • Press off drive shaft. Engage the snap ring with gentle blows (plastic hammer). When installing. remove gaiter from swinging arm. e Caution: Drive shaft clearance when suspension is compressed: aperture in retaining ring must be horizontal. 33.24 • Determine end float and face runout. Installing drive shaft • • • Coat the splines on the output shaft with Staburags NBU 30 PTM.

The Loctite has a hardening time of at least 3 hours........... 7 Nm Locknut..................... the final tightening torque must be applied without delay.... 43 Nm [RS] (10... X Tightening torque: Free bearing journal (Thread cleaned + Loctite 2701 applied to entire length of thread on free bearing journal) .............9 screw) ....... [RS] (8........ 105 Nm • X Tightening torque: Fixed bearing journal • • (thread cleaned + Loctite 2701) ........ e Caution: X Tightening torque: When threaded connections are made using Loctite Suspension strut to swinging arm 2701............g... Loctite Rapid Cleanser 706 Loctite Order No. 70636-AC • Tighten free bearing journal................ Apply Loctite to the entire length of the thread on free bearing pin (2) and screw it in......3 2 v 2701 1 v 2701 RS330030 Installing rear swinging arm • • • • Slide swinging arm over drive shaft as far as possible until rubber gaiter connects on housing neck.. Screw in fixed bearing journal (3) with Loctite........................... 150 Nm • [RT] Attach gear shift linkage to left footrest plate. [RT] Attach brake master cylinder to right footrest plate................. Tighten fixed bearing journal..... e.......... 50 Nm [GS/R/RT] (10........................................... Secure suspension strut (1)........ 50 Nm L Note: Use acetone-based cleaning agents......... [RT] Install left and right footrest plates....9 screw) ... 33.......25 ........................8 screw) ....

........ RS RS330050 GS/RT GS330440 • • [GS] Unscrew hydraulic spring adjuster using 6 mm Allen key..... 50 Nm [GS/R/RT] (10.........Removing and installing suspension strut • • • Remove dualseat...................... 43 Nm [RS] (10........... Remove rear wheel. [RT] Remove small left/right side sections of fairing............. 22 Nm 33.......8 screw) ....... 31 5 600........9 screw) .... 50 Nm Hydraulic spring adjuster at footrest plate ..... X Tightening torque: Suspension strut on swinging arm/rear frame [RS] (8................. BMW No........9 screw)....................................26 ..... Remove/install suspension strut.....

.......20 [GS/R/RT] Removing and installing rear ABS sensor ...................13 [RS] Removing and installing rear brake disc (attached to rear wheel drive) ..............................................................................................................17 ...............................................................................................................................................................................................................................................................................................................................................................................10 Assembling rear brake caliper ..........19 [RS] Removing and installing rear ABS sensor ............................................16 [GS/R] Removing and installing front ABS sensor [RT] Removing and installing front ABS sensor [ABS] Adjusting front sensor gap Marking sensor wheel ...........................................................12 Dismantling rear brake caliper ..............................................................................................................................................................7 Dismantling and assembling front brake caliper .........................................................12 Assembling rear brake caliper ............................................................................................................8 Assembling front brake caliper ...8 Dismantling front brake caliper .................19 ...................................................................18 .........................................14 [GS/R] Removing and installing rear brake disc (attached to rear wheel hub) ..................................................................1 ...........................11 [GS/R/RT] Dismantling and re-assembling rear brake caliper .............................................................................15 [RS] Removing and installing front ABS sensor ........................... 3 Removing and installing front brake caliper .....................10 Dismantling rear brake caliper ..............................................................................12 Removing and installing front brake disc ...................................................................................................................................21 34.......................................................................................................................9 [RS] Dismantling and assembling rear brake caliper .....................................................................................................................................................19 Checking and adjusting sensor gap ....8 Removing and installing rear brake caliper ...................................................................................................................................................................................................................34 Brakes 34 Contents Page Technical Data .............14 [RT/R] Removing and installing rear brake disc (attached to rear wheel drive) ...............................

........................................29 .........23 ............................24 Removing and installing rear brake master cylinder .................................................................................................................23 Checking and adjusting sensor gap ............................................22 Checking and adjusting sensor gap ........................................................................................................28 ...............................................................................................................33 ..................................................30 Installing the ABS relay base .............24 Adjusting specification for handbrake lever ....................................................................Contents Page [RS] Adjusting rear ABS sensor gap Marking sensor wheel ................................................................................................................32 ...............25 Removing and installing brake pedal Removing and installing ABS unit Removing the ABS unit Installing the ABS unit ..................25 Checking and adjusting relief clear-ance of piston rod ..................................................................................................................................................................22 ..........22 [GS/R/RT] Adjusting rear ABS sensor gap Marking sensor wheel .......28 Removing and installing ABS relay and relay base Removing ABS relay ..........................................................................................................................................................................23 Removing..................... dismantling and assembling front brake master cylinder .....................................................................................................................................................................................................................................................26 .............................................29 Installing the ABS relay ................................................................ installing........................................................................................................................29 Removing ABS relay base .......................................................................................................................................30 Removing and installing brake line (with ABS) Removing and installing front ABS brake line ...............2 ..........................................27 .......................................................................................................................32 Removing and installing rear ABS brake line 34..................................

00787) Brake pad surface area cm2 41.1969± 0.34 Technical Data R 1100 RS Brake fluid DOT 4 Minimum lining thickness mm (in) 1. mm (in) 285 (11.5 (6.3386) Piston diameter in handlebar lever cylinder mm (in) 20 (0. in brake caliper mm (in) 38 (1.5 (0.55 (0.1969) Minimum thickness mm (in) 4.4325) (sq.22) Brake disc thickness mm (in) 5.1772) Front wheel Brake pad surface area cm2 (sq.5) Piston dia.45. in foot brake cylinder mm (in) 12 (0.0.5 (0.0079) Brake disc thickness mm (in) 5± 0. in brake caliper mm (in) 32/34 (1.059) Brake disc dia..55 (0....45.02165) Brake pad Semi-metallic 34..0 (0. mm (in) 305 (12.1811) Permissible lateral runout mm (in) 0.4724) Sensor gap.in) 100 (15.3 .0.6 (0. front mm (in) 0.496) Piston dia.0177.787) Sensor gap.0177.0. rear mm (in) 0...0.1 (0.20 (0.02165) Brake pad Sintered metal Rear wheel Brake disc dia.003937) Minimum thickness mm (in) 4..2598/1.in) Piston dia.

rear mm (in) 0.0.866) Brake disc thickness mm (in) 5.1969) Minimum thickness mm (in) 4. front mm (in) 0.2598/1.4 Semi-metallic .in) Piston dia..0 (0.5 (0.1969± 0.02165) Brake pad 34.0.177) Permissible lateral runout mm (in) 0. mm (in) 305 (12. mm (in) 276 (10..15 (0.0059) Brake pad surface area cm2 34 (5.0..1 (0.0177...55 (0.5 (0.0.02165) Brake pad Semi-metallic Rear wheel Brake disc dia.1772) Front wheel Brake pad surface area 2 cm (sq.45.0079) Brake disc thickness mm (in) 5± 0..787) Sensor gap. in brake caliper mm (in) 32/34 (1.in) 100 (15..4724) Sensor gap.27) (sq.3386) Piston diameter in handlebar lever cylinder mm (in) 20 (0. in brake caliper mm (in) 26 (1..45.55 (0.0177. in foot brake cylinder mm (in) 12 (0.Technical Data R 1100 RT Brake fluid DOT 4 Minimum lining thickness mm (in) Wear indicator Brake disc dia.0236) with insulating piston Piston dia.003937) Minimum thickness mm (in) 4.5) Piston dia.

02165) Brake pad Semi-metallic Semi-metallic 34..787) Sensor gap. mm (in) 276 (10.in) 4.1772) 100 (15. mm (in) 305 (12..0.3386) 32/34 (1.177) 4...0059) 0..45.1969) 5..55 (0.10236) Piston dia.. in foot brake cylinder mm (in) 13 (0.. front mm (in) 0.0177.866) Brake disc thickness mm (in) 5..5 (0.003937) 5± 0.45.5 (0.0177.1969) Minimum thickness mm (in) 4.787) 20 (0.0.0059) Brake pad surface area cm2 34 (5.0236/1..866) 276 (10.5) Piston dia.0.0 (0..55 (0.27) 34 (5.27) (sq.0.55 (0.Technical Data R 850 GS R 1100 GS Brake fluid DOT 4 DOT 4 Minimum lining thickness mm (in) Wear indicator Wear indicator Brake disc dia.512) 13 (0..003937) Minimum thickness mm (in) 4.5 (0..0.5 .0079) 305 (12.15 (0.5 (0.0..10236) 26/28 (1.in) Piston dia.1772) Front wheel Brake pad surface area 2 cm 100 (15.15 (0.0..1969± 0.45.0177.0 (0.0079) Brake disc thickness mm (in) 5± 0.512) Sensor gap.3386) Piston diameter in handlebar lever cylinder mm (in) 20 (0.02165) 0.0.2598/1.0236/1..1 (0.55 (0.5) (sq.02165) 0. in brake caliper mm (in) 26/28 (1.177) Permissible lateral runout mm (in) 0.0177.02165) Brake pad Semi-metallic Semi-metallic Rear wheel Brake disc dia.1 (0. rear mm (in) 0.2598/1.1969± 0.45. in brake caliper mm (in) 32/34 (1.

. mm (in) 276 (10.1969) 5.02165) Brake pad Semi-metallic Semi-metallic Rear wheel Brake disc dia.3386) 32/34 (1..02165) 0.1772) 100 (15..5 (0.15 (0.4724) 12 (0.27) Piston dia.15 (0..0059) Cast wheel Brake pad surface area cm2 34 (5.6 (0.45.0059) Cast wheel 0.0236/1. mm (in) 305 (12.55 (0.866) 276 (10.55 (0.0079) 305 (12.5) (sq.3386) Piston diameter in handlebar lever cylinder mm (in) 20 (0. rear mm (in) 0.0.5 (0.10236) with insulating piston with insulating piston Piston dia.... front mm (in) 0..0 (0.2598/1.0177.1772) Front wheel Brake pad surface area 2 cm 100 (15.55 (0..1811) 4. in brake caliper mm (in) 26/28 (1.10236) 26/28 (1.1 (0.02165) Brake pad 34.15 (0.0.5 (0.4724) Sensor gap. in foot brake cylinder mm (in) 12 (0..0.6 Semi-metallic Semi-metallic .0.1 (0.0.in) 34 (5.5) Piston dia..0059) Spoked wheel 0.0177.003937) 5± 0.15 (0.45.787) Sensor gap..003937) Minimum thickness mm (in) 4...0177.0059) Spoked wheel mm (in) 0.55 (0. in brake caliper mm (in) 32/34 (1.0.in) 4.2598/1..0.27) (sq.866) Brake disc thickness mm (in) 5.0 (0.0.45.177) Permissible lateral runout mm (in) 0.1969± 0.0177.1969) Minimum thickness mm (in) 4..45.1969± 0.02165) 0.787) 20 (0.Technical Data R 850 R R 1100 R Brake fluid DOT 4 DOT 4 Minimum lining thickness mm (in) Wear indicator Wear indicator Brake disc dia.0236/1.0079) Brake disc thickness mm (in) 5± 0.

.......7 ....Removing and installing front brake caliper 2 1 2 RS340020 • • Drain fluid from brake system. e Caution: RS340050 • • Force back the brake pads/pistons (arrows)........ • • • • e Caution: Use new sealing rings (2)........ X Tightening torque: Brake caliper to slider tube .. because brake fluid destroys paint... 15 Nm Bleed screw at brake caliper .... mask off the brake caliper with tape....... 7 Nm 34.. 40 Nm Brake hose to brake caliper ... Do not damage brake pads.. if necessary. e Caution: [RS/R/RT] Do not scratch the wheel rim.............. Fill/bleed the brake system... Do not damage brake pads...... Carefully remove the brake calipe.. Do not allow brake fluid to come into contact with painted parts of the motorcycle... Install in the reverse order of work.. Force back the brake pads/pistons.... Unscrew the brake caliper..... Detach brake line (1)...

risk of injury.. press the pistons fully back with resetting tool (7).. Carefully press out brake pistons (2)..8 • • If necessary.... Assembling front brake caliper • • Coat new sealing rings (3. Remove the two sealing rings (3.. 7 Nm Do not tilt the brake pistons when installing.....4) with brake fluid and install. using a compressed air gun at the brake line connection... • • Hold a cloth over the brake caliper. • Dismantling front brake caliper • • • • • Remove the brake caliper.34 1 500 2 3 4 7 1 RS340070 Dismantling and assembling front brake caliper e Caution: e Caution: • The brake caliper halves must not be un-screwed! Do not allow your fingers to become trapped between the pistons. Coat brake caliper pistons (2) with brake fluid and insert.. 34 1 500. Remove keeper from retaining pin (1).... Seal the bleed screw.. Examine the brake caliper pistons for damage.. Pull the brake pads out downwards.. BMW No. X Tightening torque: e Caution: Bleed screw at brake caliper . Drive out the retaining pin (1) from the wheel side...4) from the left/ right brake cylinder bores.. Install the brake pads.. .. 34.

0177............ 4 Nm Detach the brake line from the brake caliper...................RS 1 2 RS340120 Removing and installing rear brake caliper • Drain fluid from brake system e Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle.55 mm ( 0. [ABS] Check sensor gap and adjust if necessary with spacing plate.................9 . Unscrew the brake caliper (2).... 15 Nm Bleed screw at brake caliper [RS] ...... because brake fluid destroys paint. 40 Nm Brake line to brake caliper. [RS/ABS] Detach the sensor line plug (1)..................... e Caution: Renew sealing rings for brake line...... 7 Nm [GS/R/RT] ................. 0..............0.... Force back the brake pads/pistons.. Do not damage brake pads... Install in the reverse order of work.... • • • • • • • Sensor gap:... Fill/bleed the brake system.. 34........................45.....02165in) X Tightening torque: Brake caliper to rear wheel drive ... [R/RT] To bleed........... detach the brake caliper and position it with the bleed nipple at the highest point.....0.

.... Take out dust protection sleeve (6) at left/right...... .... working at low air pressure. Drive out retaining pins (2) from the wheel side..... 7 Nm 34.4 1 3 2 5 6 8 7 RS340133 [RS] Dismantling and assembling rear brake caliper • • Dismantling rear brake caliper e Caution: The two halves of the brake caliper must not be unscrewed! • • • • • • Remove protective cap (1). Inspect the brake caliper piston for hairline cracks/score-marks/other damage... Seal the bleed screw. Carefully press our brake piston (7) with a compressed air gun at the connecting bore..10 Hold a cloth over the brake caliper... e Caution: Do not allow your fingers to be trapped by the piston.... Take out clamping pin/curved spring (3/4). risk of injury! • • Remove sealing ring (8) from the left/right wheel brake cylinders. X Tightening torque: Bleed screw at brake caliper . Take out brake pads (5)..

• Insert the dust protection sleeve (6) at left and right 34 1 500 RS340150 • Before installing the new brake pads. BMW No.Assembling rear brake caliper • • Coat new sealing rings (8) with brake fluid and insert them into the left/right brake cylinders. press the pistons back into the brake calipers with the resetting device. 34. 34 1 500. Coat both brake caliper pistons (7) with brake fluid and install them. e Caution: Do not tilt the brake pistons when assembling.11 .

. . risk of injury.. Coat both brake caliper pistons with brake fluid and install them. • Insert brake pads and secure with retainers. Insert locating plate (5) into brake caliper.. Seal the bleed screw....... work at low air pressure e Caution: Keep fingers away from gap between pistons and side contact face of brake pads... Carefully press out brake piston (3) with a compressed air gun applied to the connecting bore. • • e Caution: Do not tilt the brake pistons when installing. Take out brake pads.. Bleed screw at brake caliper ...... Inspect the brake caliper piston for hairline cracks/score-marks/other damage.12 • • Coat the adapter plate locating pins with Shell Retinax A and install the adapter plate.... 4 Nm Hold a cloth over the brake caliper piston. Drive out retaining pin (2)..1 5 2 3 4 GS340140 [GS/R/RT] Dismantling and reassembling rear brake caliper Assembling rear brake caliper • Dismantling rear brake caliper • • • • Remove keeper (1).. Remove sealing rings (4) from left/right cylinder.. L Note: The installed position must be correct (arrow pointing in forward-travel direction).. 34.. X Tightening torque: • • • Coat the new sealing rings with brake fluid and insert them into the left/right brake caliper cylinders.

Degrease brake discs before installing.02165 in) 34.....55 mm (0...... Remove/install brake disc......... 0.................... if exchanged...0...RS RS340080 Removing and installing front brake disc • • • Remove front wheel........ Sensor gap:. apply a new sensor gap measuring mark................. X Tightening torque: Brake disc to front wheel [RS/RT].....0177.... 21 [GS] (clean thread + Loctite 243)......... L Note: Installed direction (arrow) of brake discs must be correct....45..............0...13 ....... 24 [R] Cast alloy front wheel .......... 21 (R) Spoked front wheel (clean thread + Loctite 243)................. 24 Nm Nm Nm Nm e Caution: Check/adjust sensor gap....

. • • • Remove brake disc. L Note: Mark the installed position of the brake disc..14 Brake disc to rear wheel drive (clean thread + Loctite 243)...... Install in the reverse order of work........02165 in) e Caution: [ABS] Check sensor gap and adjust with spacing X Tightening torque: plates if necessary.55 mm (0.... Remove rear wheel. Remove the brake caliper.. 21 Nm 34. j 120 1 v v 273 243 GS340161 RS340160 • Heat brake disc retaining screws (1) to 120 °C/ remove.0177.... • • [ABS] Check sensor gap and adjust with spacing plates if necessary... 21 Nm .0. Install in the reverse order of work..45. 0.0.....0177.45. Sensor gap:.....0.... Remove rear wheel..[RS] Removing and installing rear brake disc (attached to rear wheel drive) [GS/R] Removing and installing rear brake disc (attached to rear wheel hub) • • • • Remove the brake caliper.. so that e Caution: vertical runout of the sensor wheel does not change..........55 mm (0....0.... 0. Degrease the brake disc before installing.02165 in) X Tightening torque: Brake disc to rear wheel drive (clean thread + Loctite 273). Sensor gap:... Degrease the brake disc before installing. [ABS] If the brake disc and therefore the sensor wheel are renewed.. the disc’s vertical runout must be determined/marked......

0......0.. L Note: Mark installed position of brake disc.02165 in) X Tightening torque: Brake disc to rear wheel drive (clean thread + Loctite 273).45..[RT/R] Removing and installing rear brake disc (attached to rear wheel drive) • • Remove the brake caliper. 0.....0177... Sensor gap:. [ABS] If the brake disc and therefore the sensor wheel are renewed.... 21 Nm 34.55 mm (0...... so that lateral runout of sensor wheel is not changed. e Caution: [ABS] Check sensor gap and adjust with spacing plates if necessary..15 . • • Install in the reverse order of work.. the disc’s lateral runout must be determined/marked. Remove rear wheel....... Degrease the brake disc before installing. 1 RT340162 • Heat the brake disc retaining screws (1) to 120 °C/remove..

.... 4 Nm 34... Check sensor gap and adjust if necessary with spacer plate (3).0... Sensor gap:.......0...........45... 0.02165 in) X Tightening torque: Sensor .1 3 2 RS340090 [RS] Removing and installing front ABS sensor • • • • • Remove the right side section of the fairing. Install in the reverse order of work........55 mm (0.....16 ..0177.... Remove front mudguard. e Caution: Run the sensor line correctly...handtight.. Separate plug connector (1) in sensor line... Remove sensor (2) with Torx T 25.

. Sensor gap:.. Remove sensor (2) with Torx T 25.45.0...17 . 4 Nm 34.........3 2 1 GS340090 [GS/R] Removing and installing front ABS sensor • • • • • • [GS] Remove front wheel.....0177..... Separate plug connector (1) in sensor line. [GS] Remove front mudguard. Remove fuel tank..handtight.......55 mm (0... e Caution: Run the sensor line correctly...... 0.02165 in) X Tightening torque: Sensor ......0. Install in the reverse order of work...... Check sensor gap and adjust if necessary with spacer plate (3)....

0. 4 Nm 34... Remove front mudguard..55 mm (0.. Sensor gap:. Remove sensor (2) with Torx T 25...........02165 in) X Tightening torque: Sensor .handtight.0. e Caution: Run the sensor line correctly....45.........18 .....0177.....3 2 1 RT340090 [RT] Removing and installing front ABS sensor • • • • • Remove right side sections of fairing. Check sensor gap and adjust if necessary with spacer plate (3).0........ Install in the reverse order of work....... Separate plug connector (1) in sensor line.

e Caution: If parts are replaced (brake disc etc. If necessary. 00 2 510 and measuring shoe (2). Check/adjust at the marked point... BMW No. Measure axial runout over the entire circumference. Attach dial gauge holder (1).45.00 2 510 34 2 510 2 00 5 500 1 RS340100 [ABS] Adjusting front sensor gap Checking and adjusting sensor gap Marking sensor wheel • • • • • • • Take load off front wheel/lift clear of ground.19 . remove/install sensor with Torx T 25 and adjust sensor gap with spacing plates. 0.0177.. 34. Remove the old marking..55 mm (0. BMW No.0.. BMW No. 00 2 500. to fork slider tube. make a permanent mark at the point where the sensor is farthest away from the sensor wheel (arrow).02165 in) e Caution: After adjusting.) and a used or previously marked sensor wheel is installed. 34 2 510. Using a paint pencil. with dial gauge. check that the sensor wheel is free to turn at all points on its circumference. Sensor gap:. Zero the dial gauge.0. the sensor ring must be measured and marked again.

0....45... Install in the reverse order of work. Using Torx T 25... Separate the plug connector (2) in the sensor line... Run the sensor line correctly. Sensor gap:....0..02165 in) X Tightening torque: Sensor ...... detach sensor (1)........ 4 Nm 34................55 mm (0..0177.2 1 3 RS340170 [RS] Removing and installing rear ABS sensor • • • • Remove brake caliper but do not detach brake line.0.. e Caution: Check sensor gap and adjust if necessary with spacer plates (3)...20 ...handtight..

21 ..0. 4 Nm 34... Separate plug connector (2) in the sensor line.45....0177. Detach sensor (1) with Torx T 25.. Coat O-rings with oil before installing e Caution: Run the sensor line correctly...........3 1 2 GS340170 [GS/R/RT] Removing and installing rear ABS sensor • • • • • • [RT] Remove small right side section of fairing..02165 in) X Tightening torque: Sensor .55 mm (0.. Install in the reverse order of work. Check sensor gap and adjust if necessary with spacer plates (3)... clean the sensor bore...... 0..handtight........ Before removing/installing. Sensor gap:..........0.....

. 34 2 510....) and a used or previously marked sensor wheel is installed... 36 4 600... e Caution: After adjusting....0177... Fasten measuring adapter. BMW No. 4 Nm .. Remove the old marking. with a M 8 x 60 mm bolt to the brake caliper mount.. 00 2 510 and measuring shoe (2)...55 mm (0. with dial gauge. 34. remove/install sensor with Torx T 25 and adjust sensor gap with spacing plates... BMW No....0.02165 in) X Tightening torque: Sensor ... BMW No... the sensor ring must be measured and marked again.handtight. e Caution: If parts are replaced (brake disc etc...... Measure radial runout over the entire circumference. Make a permanent paint pencil mark at the point where the sensor wheel is farthest away from the sensor (arrow). Zero the dial gauge...45..00 2 510 34 2 510 2 00 5 500 1 RS340180 [RS] Adjusting rear ABS sensor gap Checking and adjusting sensor gap Marking sensor wheel • • • • • • • • • Remove the brake caliper... 00 2 500..0. Sensor gap:.... Attach dial gauge holder (1).. 0... BMW No..22 Check/adjust at the marked point In necessary. check that the sensor wheel is free to turn at all points on its circumference... Remove rear wheel..

. Sensor gap:.. 00 2 510.0...34 2 520 00 2 510 GS340181 [GS/R/RT] Adjusting rear ABS sensor gap Marking sensor wheel • • • • • • Before removing/installing.. 34 2 520 and dial gauge.. 0. Checking and adjusting sensor gap • • Check/adjust at the marked point If necessary.0177. remove/install sensor with Torx T 25 and adjust sensor gap with spacing plates.. to sensor mount. Zero the dial gauge. Measure axial runout over the entire circumference....... the sensor ring must be measured and marked again... Bolt dial gauge holder with measuring shoe..02165 in) X Tightening torque: Sensor ...) and a used or previously marked sensor wheel is installed.0..... 4 Nm e Caution: If parts are replaced (rear wheel etc.... BMW No. Remove the old marking....45.handtight... detach the sensor... check that the sensor wheel is free to turn at all points on its circumference... Make a permanent paint pencil mark at the point where the sensor wheel is farthest away from the sensor (arrow)......23 . 34. e Caution: After adjusting.. clean sensor and bore......55 mm (0.. extension BMW No. Using Torx T 25..

Press piston (4) in slightly.....) . because brake fluid destroys paint.. e Caution: e Caution: Never tighten the grub screw by more than this additional half-turn... e Caution: Sealing lips of sleeves face the pressure chamber. Install in the reverse order of work... Piston (4) is spring-loaded.. • • Seal grub screw (7) with paint........ or else the brake could fail or be locked on.... then tighten it further by precisely one half-turn........ installing..24 X Tightening torque: Pivot pin (2) ..... • • • Take out piston (4) with spring (6). L Note: The pivot pin is secured with Tuflok blue. • • • • • Adjusting specification for handbrake lever • Clean grub screw (7).. Remove handbrake lever pivot pin (2).. Grease thrust pin (arrow) at handlebar lever lightly with Shell Retinax A. 34. coat it with Loctite 270 and screw it in until there is no play at the handlebar lever.. Slacken off stop screw (5)..... Pull off dust protection sleeve (3)..5 2 6 3 1 4 7 RS340110 Removing. dismantling and assembling front brake master cylinder • Drain fluid from brake system.... Remove cover (1).. • Fill/bleed the brake system.. e Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle.. Threads secured with this material can be un screwed and retightened several times.. 8 Nm (Threads secured with Tuflok blue can be un screwed and tightened several times.. Coat pistons and sleeves with brake fluid before installing...

.. BMW No.. 9 Nm 34. e Caution: Bleed the brake system carefully. GS340200 • Insert a feeler gauge of the correct thickness between the adjusting screw/brake lever and the stop (arrow).. [RT] Detach brake line (1). Check/adjust piston rod snifting-action play. e Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle.Removing and installing rear brake master cylinder Checking and adjusting relief clearance of piston rod RS GS 1 2 3 2 1 4 RS340190 • Drain fluid from brake system. [RT] Detach hose (2) from master cylinder. Feeler gauge thickness:.2 mm (0. lock it in this position. Install in the reverse order of work. because brake fluid destroys paint.. 13 1 500... X Tightening torque: Master cylinder to footrest plate .... Tighten non-reusable hose clip (2) with pliers.. Insert piston rod (2). turning to right until clearance is present. Turn the piston rod carefully to the left to withdraw it again until no clearance is present. [RS/GS/R] Release pin (3). [RT] Remove brake fluid reservoir with hose (2) and master cylinder. [RT] Release pin (3). [RT] Detach brake master cylinder (4). • • • • • • • • • • • [RS/GS/R] Detach brake line (1) and hose (2). Tighten locknut/check clearance again..25 ..00787 in) • • • • Release locknut (1)... [RT] Remove right side sections of fairing........ 0...... [RS/GS/R] Detach brake master cylinder (4).

............ Remove brake pedal with spiral spring.. Remove brake pedal retaining pin (1)...GS 1 RS340220 Removing and installing brake pedal • • • • • Release pin on brake linkage......... The brake light must come on as soon as the rear brake begins to take effect.. e Caution: Check/adjust piston rod relief clearance.... 37 Nm 34...... See removal and installation of brake master cylinder...... Lubricate pivot bushing with Shell Retinax A...26 . Install in the reverse order of work. X Tightening torque: Brake pedal to footrest plate (free from grease)....

27 . 34.6 1 5 2 3 4 RS340010 Removing and installing ABS unit e Caution: Work on the ABS unit is only to be performed by an authorized BMW workshop.

....... Line connections must be protected against dirt penetration...5 Nm Battery +/M4 .......... 15 Bleed screw at ABS unit .. if ncessary seal/cover over.......... Install the fuel tank... Pull off the central plug (5). 3 Nm • Install a new cover......... • • • • Reconnect the 2-pin plug in the correct position.... make sure that all cables are correctly located in their cable entries........ e Caution: Make sure the cable is not at an angle.............. 3. Tighten the nuts.......... Discard the old cover..... • • • • • Remove cover (2) from ABS control unit.. pushing the two halves fully together........................... or its insulation may be damaged.......... press the lock in with a screwdriver and pull the cover up......... and press the two wires into the center (smaller) cable entries... Install the ABS unit (6).........Removing the ABS unit Installing the ABS unit • • • • Remove fuel tank............ Press the two cables into the remaining free cable entries.. Remove the ABS unit 6)... Detach wires (3). e Caution: Always use new self-locking nuts.... 9 34.....28 Nm Nm Nm Nm . e Caution: Switch off ignition. Connect the central plug (5)............ 5 Brake line to ABS unit ...... Push the two plugs for the connecting cable/ wiring harness onto the threaded pins with the crimp at the front................. Pull off 2-pin plug (4)... • Hold the front brake lever against the handlebar grip with a rubber band (to close the brake fluid feed bore)............. X Tightening torque: Battery —/M5 ....... Disconnect ABS brake lines (1) at ABS uni e Caution: If brake fluid escapes.................. Fill/bleed the brake system........ • • • Screw ABS brake lines (1) to ABS unit. X Tightening torque: ABS unit to holder M6 screw . disconnect and insulate the ground (earth) strap... it may damage paint............ e Caution: When sliding the cover on.............. 9 M6 screw (Torx) ......

Removing and installing ABS relay
and relay base
Removing ABS relay

Installing the ABS relay




1
4

e Caution:

Make sure the cable is not at an angle, or its insulation may be damaged.

3
2



RS340200

e Caution:

Switch off ignition, disconnect and insulate the
ground (earth) strap.



Remove cover (1) from ABS control unit, press in
the lock with a screwdriver and pull the cover up.
Discard the old cover (1).
Detach lines (2) and discard nuts.

e Caution:

Make sure the cable is not at an angle or its insulation may be damaged.




Insert the ABS relay with the FAG inscription
facing the detent hook.
Tighten the screws at the 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 bottom, black at top).
Attach black engine cable to left threaded pin
(M5) with crimp at back.


Attach 2-pin plug in correct position, pushing it
on fully and press the two wires into the center
(smaller) cable entries.
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.
Tighten the nuts.

e Caution:

Always use new selflocking nuts.

Install a new cover (1).

e
Caution:
When sliding the cover on, make sure that all cables
are correctly located in their cable entries. Scrap
the old cover.

Pull off 2-pin plug (3).
Take out relay base (4).
Slacken off screws on relay base by app. 2 turns
with Torx T20.
Pull the relay off upwards.

34.29

Removing ABS relay base

Installing the ABS relay base

e
Caution:
Switch off ignition, disconnect and insulate the


ground (earth) strap.



Remove cover (1) from ABS control unit, press in
the lock with a screwdriver and pull the cover out
upwards.
Scrap the old cover (1).
Detach the wires (2); scrap the nuts.

e Caution:

Make sure the cable is not at an angle, or its insulation may be damaged.

Bend up the contact interlock on the plug.
Insert the contact into the relay base.

e

Caution:
The contact must be heard to engage and must be
firmly located.


Insert the ABS relay with the FAG inscription facing the detent hook.
Insert a Torx screw into the ring shoe of the red
engine cable.

L Note:

The crimp side is towards the screw head.






Pull off the 2-pin plug (3).
Take out relay base (4).
Remove screws at relay base with Torx T20.
Remove the ABS relay.
Press the contact interlock out of 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.

e Caution:

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.

34.30

e Caution:

The same Torx screws must be re-used because of
their self-locking effect.
When inserting the screws again, make sure that
they pick up with the existing thread in the sheetmetal element.
Failing this, vibration could cause the screws to
work loose.




Place the ring show (with two cables) on the bore
of the insert at the rear of the relay base, with the
crimp side towards the relay base, and screw on
together the red engine cable, using the Torx
screw.
Use the second Torx screw to secure the flat
plug to the relay.
Press the contact interlock into the relay base at
the side.
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 bottom, black at top).
Attach black engine cable to left threaded pin
(M5) with crimp at back.

e Caution:

Make sure the cable is not at an angle or its insulation may be damaged.




Push the 2-pin plug fully on in the correct position and press the two wires into the center
(smaller) cable entries.
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.
Tighten the nuts.

e Caution:

Always use new self-locking nuts.

Install a new cover (1).

e
Caution:
When sliding the cover on, make sure that all cables
are correctly located in their cable entries.

34.31

Removing and installing brake line
(with ABS)

RS

RS340040

Removing and installing front ABS
brake line

34.32

RS

RS340030

Removing and installing rear ABS
brake line

34.33

Drain fluid from brake system.

e
Caution:
Do not allow brake fluid to come into contact with
painted parts of the motorcycle, because brake fluid
destroys paint.





[ABS] Removing fuel tank.
[RS] Removing front section of front mudguard.
[GS] Removing front mudguard.
Remove brake lines.
Install in the reverse order of work.

e
Caution:
Renew sealing rings for brake line.
Attach brake line to master cylinder so that it cannot
become kinked or abraded when the handlebar 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.

X
Tightening torque:
Brake line to fitting ....................................... 15 Nm
Brake line to front/rear brake caliper ............ 15
Brake line at fluid distributor ......................... 15
Flow distributor to slider tube bridge
[RS/GS] ........................................................ 9
Flow distributor to holder/slider tube
[R/RT]............................................................ 9
Bleed screws ................................................. 7
Bleed screw on rear brake caliper
[GS/R/RT] ..................................................... 4
[ABS] Bleed screw at ABS unit ...................... 9
[ABS] Distributor block to frame..................... 9
[ABS] Brake line at ABS unit ........................ 15

34.34

Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm

36 Wheels and tyres
36

Contents

Page

Technical Data ............................................................................................................................... 3
Removing and installing front wheel
Removing front wheel
Installing front wheel

.................................................................................7

...................................................................................................................7

......................................................................................................................7

Removing and installing wheel bearings

..............................................................................8

[RS/R/RT] Removing and installing rear wheel (cast alloy)
Removing rear wheel
Installing rear wheel

..................................................................................................................10

.....................................................................................................................10

[GS/R] Removing and installing rear wheel (spoked)
Removing rear wheel
Installing rear wheel

................................10

............................................11

..................................................................................................................11

.....................................................................................................................11

Static balancing of front wheel/rear wheel
Checking front/rear wheel rim for runout

..................................................................12

.....................................................................13

[GS/R (spoked wheel)] Removing and installing spokes
[GS/R (spoked wheel)] Centering wheel rim
Centering horizontal runout

.....................................14

...............................................................14

.....................................................................................................14

36.1

36.2

36

Technical Data

R 1100 RS

Rim size
front

3.50 x 17 MT H 2

rear

4.50 x 18 MT H 2

Max. vertical/lateral runout

Cast wheel

front

mm (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)

front

bar (psi)

rear

bar (psi)

With pillion passenger

2.5 (36.26)

With pillion passenger and luggage
front
rear

2.7 (39.16)
2.5 (36.25)

bar (psi)
bar (psi)

2.9 (42.06)

36.3

Technical Data R 1100 RT Rim size front 3.5 (36.0197) rear mm (in) 0.3 (0.5 (36.0118) Tyre size Cast wheel front 120/70 ZR 17 Tubeless rear 160/60 ZR 18 Tubeless Tyre pressure (cold) Solo front bar (psi) 2.50 x 17 MT H 2 rear 4. vertical/lateral runout Cast wheel front mm (in) 0.7 (39.16) bar (psi) 2.26) rear bar (psi) 2.9 (42.4 .26) front bar (psi) 2.5 (0.25) bar (psi) 2.06) With pillion passenger With pillion passenger and luggage front rear 36.50 x 18 MT H 2 Max.5 (36.91) rear bar (psi) 2.2 (31.

3 (0.91) 2.3 (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) 2.26) 2.0512) 1.5 (36.7 (39.5 (36.5 (36.50 x 19 MT H 2 rear 4.3 (0.0512) 1.16) 2.5 (36.5 (36.9 (42.5 (36.3 (0.06) 2.50 x 19 MT H 2 2.2 (31.2 (31.00 x 17 MT H 2 4.06) With pillion passenger With pillion passenger and luggage front rear 36.26) 2.Technical Data R 850 GS R 1100 GS front 2.5 .00 x 17 MT H 2 Spoked wheel Spoked wheel Rim size Max.16) bar (psi) 2.7 (39.25) 2.26) front bar (psi) 2.0512) rear mm (in) 1.9 (42.91) rear bar (psi) 2. vertical/lateral runout front mm (in) 1.25) bar (psi) 2.26) rear bar (psi) 2.

7 (39.0197) 0.3 (0.06) 2.7 (39.9 (42.5 (36.0118) 0.16) bar (psi) 2.26) rear bar (psi) 2.00 x 17 MT H 2 Cast wheel Cast wheel Max.50 x 17 MT H 2 3.0512) rear mm (in) 1.26) 2.50 x 18 MT H 2 2.00 x 17 MT H 2 4.2 (31.0118) Spoked wheel Spoked wheel front mm (in) 1.0197) rear mm (in) 0.3 (0. vertical/lateral runout front mm (in) 0.91) 2.50 x 18 MT H 2 4.06) With pillion passenger With pillion passenger and luggage front rear 36.5 (36.5 (36.2 (31.3 (0.3 (0.16) 2.50 x 17 MT H 2 rear 4.5 (0.50 x 18 MT H 2 Spoked wheel Spoked wheel front 2.50 x 18 MT H 2 rear 4.9 (42.0512) 1.26) front bar (psi) 2.3 (0.25) bar (psi) 2.0512) 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) 2.5 (36.3 (0.6 .0512) 1.5 (36.91) rear bar (psi) 2.Technical Data R 850 R R 1100 R Rim size Cast wheel Cast wheel front 3.26) 2.25) 2.5 (36.5 (0.

.............. Remove brake calipers.... Tighten retaining screw (1)...7 ....... e Caution: [RS/R/RT] Do not scratch rim...... mask off with tape if necessary...... Loosen clamping screws (2)..... [RS/RT] Install front mudguard..... L Note: Do not apply handbrake lever with brake calipers removed/front wheel removed..0177. Remove spacer bushing (3) and speedometer drive......... 22 Nm Brake caliper to slider tube . • • • • • Remove retaining screw (1).0..................02165 in) X Tightening torque: Screw connection. Remove quick-release axle..... Remove front wheel.45. 30 Nm Clamping screws.55 mm ...... Do not tilt the brake caliper: risk of damage to brake pads.. ABS sensor gap ... Press forks down firmly several times... [ABS] Check sensor gap and adjust if necessary......... Tighten clamping screws (2).. e Caution: Anti-twist device (arrow) on speedometer drive is located in front of stop on slider tube... 0..... Install brake calipers..........0. (0.. 40 Nm 36.. quick-release axle ...... Install spacer bushing and speedometer drive... • • • • • • • Apply a light coating of Molykote paste to the quick-release axle/install it....3 2 1 RS360011 Removing and installing front wheel Installing front wheel Removing front wheel • • • • [RS/RT] Remove front mudguard.. Install front wheel.. quick-release axle .

8 • • RS360023 Press out spacing bushing (1) and wheel bearing (2) with drift. 00 8 572. in vise and place wheel on it with the broad bearing in contact with the arbor. Place spacing ring. BMW No. 36 5 530/ into new bearing. BMW No. Press reducing bushing out of bearing with drift. . 36. BMW No. Degrease bearing seats. 31 4 800. 36 5 511. BMW No. and internal puller 21/3.Removing and installing wheel bearings 36 5 530 1 2 • RS360021 • Remove shaft seal. between wheel hub/right side of wheel and claws of internal puller. j 80 00 8 572 00 8 574 31 4 800 RS360024 • • • • Clamp arbor. driver and retaining ring. Heat bearing seat to 80 °C. BMW No. BMW No. Pull out wheel bearing with counter-support 22/1. 36 5 530. 00 8 574.

Drive in shaft sealing ring with drift. Insert narrow bearing (3) with drift. 36 5 512.9 . and handle. 36 5 511. 00 5 500 36 5 500 RS360026 • First insert wide bearing using drift. 36. and handle. BMW No. 00 5 500. RS360027 • • Install retaining ring and driver. BMW No. 2 00 5 500 36 5 511 RS360028 • 36 5 511 • • • Clamp arbor. 36 5 511. 00 5 500. BMW No. Bearing seat temperature 80 °C. BMW No. BMW No. 00 5 500.00 5 500 j 80 00 5 512 3 RS360025 1 • Heat bearing seat. in vise and place wheel on it with wide bearing (2) in contact with arbor. BMW No. Install spacer tube (1). 36 5 500. and handle. BMW No.

36.... [RS/ABS] Bolt on the muffler mount. Install hub cap (2).................... X Tightening torque: Screw in wheel studs handtight...... 50 Nm Final tightening.. Fit rear wheel to rear wheel drive with spacer disc (1) and insert wheel studs hand-tight...... Installing rear wheel e Caution: The spacing washer (1) and the contact faces on the rear wheel drive and the hub must be clean and free from grease............................... • • [RS/ABS] Press the muffler outwards.2 RS/R/RT 1 RS/R/RT RS360040 [RS/R/RT] Removing and installing rear wheel (cast alloy) Removing rear wheel • • [RS] Remove number plate carrier............ [RS/ABS] Detach muffler (silencer) mount/press muffler outwards/carefully remove the rear wheel........10 L Note: Insert lug on cover in recess in wheel.. 105 Nm . then tighten them in a crosswise pattern Initial tightening . e Caution: Only use wheel studs with length code 60.. Do not oil or grease wheel studs! • • Tighten wheel studs.. • • Install number plate holder..

.. [ABS] Sensor gap .....0... 105 Nm • • Install brake caliper..55 mm .....45..............[GS/R] Removing and installing rear wheel (spoked) Removing rear wheel • • Unfasten/remove brake caliper.................11 . (0.. [ABS] Check sensor gap... Do not oil or grease wheel studs! • Tighten wheel studs...0177..............0................ Installing rear wheel e Caution: Contact faces on rear wheel drive and hub must be clean and free of grease.. L Note: [GS] To remove the wheel......... 50 Nm Final tightening ........... e Caution: Only use wheel studs with length code 60...02165 in) 36.....0............... X Tightening torque: Screw in the wheel studs handtight and tighten them in a crosswise pattern Initial tightening .............. Remove rear wheel.. carefully bend the rear wheel cover to the right/do not remove it..................... • Fit rear wheel to rear wheel drive and screw in wheel studs hand-tight............

on the centering collar side with the wheel studs and spacing washer. attach mounting fixture (4). Attach adhesive weights (7) opposite heaviest point of wheel (arrow). BMW No. Lightly preload bearing with knurled nut (3). in the front wheel bearings. with knurled screws/bubble gauge (5/6). 36 3 606. 36.12 . BMW No. At the rear wheel. e Caution: Maximum balancing weight 60 g (2. 36 3 613. Allow wheel to settle. evenly distributed on both sides (left/right) of rim.1 oz. then install the balancing shaft. BMW No. Align the balancing fixture. BMW No.7 4 3 36 3 613 36 3 616 2 36 3 616 36 3 606 6 5 36 3 600 1 RS360050 Static balancing of front wheel/rear wheel • • • • • • • Install balancing shaft (1). • Repeat balancing procedure as a check. 36 3 616.). 36 3 600. with measuring bushing (2) and nut (3). Clean point of adhesion.

...... BMW No... 0...... 36 3 616... Align the balancing fixture. Check radial/axial runout...........13 .....0197 in) rear .. BMW No........ BMW No..5 mm (0..... with knurled screws/bubble gauge (5/6).. on the centering collar side with the wheel studs and a spacing washer.. Clamp locating discs... on the balancing shaft at left and right so that the shaft cannot wander.... in the front wheel bearings......0512 in) 36. 36 3 606.......... 1.... Lightly preload bearing with knurled nut (3)...0118 in) Spoked wheel front/back..... attach the mounting fixture (4). At the rear wheel.. e Caution: Only apply dial gauge to machined inner face of wheel rim. Install balancing shaft (1). BMW No.... vertical runout/lateral runo Cast alloy wheel front .........3 mm (0... 36 3 615. Prevent balancing shaft from turning by inserting pin at balancing frame... Max.3 36 3 616 4 36 3 613 2 36 3 616 36 3 606 1 6 36 3 600 5 RS360060 Checking front/rear wheel rim for runout • • • • • • • • Remove tyre........3 mm (0.......... BMW No.. 0. 36 3 613... 36 3 600. together with measuring bushing (2) and nut (3)..... then install the balancing shaft...

...... Center the wheel rim...... X Tightening torque: Spoke nipple ............... (0........ 5 Nm Grub screw ...2...0 mm ......... Unfasten spoke nipple (2)/remove spoke....................... Four spokes are therefore tightened during each centering operation......... To center the wheel..................... check vertical runout again.... Check horizontal runout with a dial gauge.................. horizontal runout which can be eliminated by centering............. 5 Nm Never attempt to compensate for the entire horizontal runout at only one or two spokes... take up slack at every 3rd spoke nipple........0787 in) L Note: Vertical runout cannot be compensated for by centering the rim...... repeat the centering operation....... [GS/R (spoked wheel)] Centering wheel rim Max....0512 in) Max....[GS/R (spoked wheel)] Removing and installing spokes 2 Centering horizontal runout GS360090 1 GS360080 e Caution: • • It is not permitted to replace more than one spoke......... permissible lateral/vertical runout............ 1 Nm ....................1............. Working forwards and backwards from the maximum and minimum value points. If necessary.......... Remove grub screw from relevant spoke nipple before tightening..3 mm .... take up slack at 2 spokes....... Install new spoke....... • • • • Unfasten grub screw (1).... Lock tightened spokes into place with grub screws................. X Tightening torque: e Caution: Spoke nipple ............ 36...... (0....................... • • Determine maximum deviation (plus (+) and minus (-))............14 • • • • • • At the point where the maximum plus and minus values occur............. After every correction of horizontal runout. the spoke nipples must be tightened on the side directly opposite the largest deviation............

......................................................................................................................................................1 ............................................................................................22 ........7 [RT] General view of fairing sections .........19 Removing and installing side stand ...........46 Frame 46 Contents Page Technical Data ....................... frame ......................................................................................................................................................................................................................................................23 [RS] Removing and installing front mudguard ........................................................11 [RT] Removing and installing inner fairing panel ............................................................17 [RT] Removing and installing lower rear section ........21 [RT] Removing and installing right footrest plate [RT] Removing and installing frame ................................................20 [RT] Removing and installing left footrest plate ........................28 ....................................................16 [RT] Removing and installing number plate mount ........14 [RT] Removing and installing luggage rack/case holder [RT] Removing and installing rear fairing ......8 [RT] Removing and installing front mudguard ........9 [RT] Removing and installing fairing sections ...........................................................................18 [RT/GS/R] Removing and installing center stand ...........15 .....................................................................26 .......................................................................................................................10 [RT] Removing and installing wind-shield ......25 [RS] Removing and installing side sections of full fairing [RS] Removing and installing wind-shield .......................12 [RT] Removing and installing upper section of fairing [RT] Removing and installing fairing holder ........................................................................................................................................................................................30 .......31 46.....................................................................................................................................................24 [RS] Removing and installing side sections of fairing ....................................29 [RS] Removing and installing top section of fairing [RS] Removing and installing fairing holder ......27 [RS] Removing and installing adjustable windshield [RS] Removing and installing inner fairing panel ................................................... 3 General view...........................13 ...............................................

...................52 Measuring wheel track offset 46..............................51 ...............................................................................38 .................................................................................................45 [GS] Removing and installing luggage rack .................................................................................................................................52 ....................................48 [GS/R] Removing and installing rear footrest plate [GS] Removing and installing front footrest plate [R] Removing and installing rear fairing Checking running gear .................................................................40 [RS/R] Removing and installing front footrest plate [GS/R] Removing and installing front mudguard [GS] Removing and installing front fairing ...........................41 ......................................................32 [RS] Removing and installing grab handle/case holder [RS] Removing and installing rear fairing ......42 .44 [GS] Removing and installing fairing holder ................................................................................................................................................................................................................36 [RS] Removing and installing rear footrest plate [GS] Removing and installing windshield ....43 .............................................................................................2 ............................................Contents Page Removing and installing frame ...49 ................50 .........................................................................................47 ..........................................................................................................................................................34 [RS] Removing and installing number plate bracket [RS] Removing and installing lower rear section Removing and installing rear section of frame [RS] Removing and installing center stand .............................................................................46 [GS/R] Removing and installing number plate bracket [GS/R] Removing and installing rear mudguard ....33 .....37 .35 ..........................................................................

3 .5 Max. mirrors mm (in) 1286 (50. front/rear Permitted total weight mm (in) kg (lb) % kg (lb) 9 (0.99) Ground clearance in normal-load position mm (in) 153 (6. height excl. with weights mm (in) 735 (28.46 Technical Data R 1100 RS Location of manufacturer’s type plate / frame number On frame.wheel track offset Unladen weight.995) 52.26) Height of seat at unladen weight mm (in) 800 (31. heel angle with 85 kg (187.3 450 (992. at right Length. full tank Axle load distribution (without rider).25) 46.496) .024) Caster angle in normal-load position mm (in) 111 (4.71/31.425 lb) rider ° 49 Max.63) Width over handlebar.with adjustable seat mm (in) 780/800/820 (30.63) Max.354) 239 (526.937) Width over pillion footrests mm (in) 667 (26.7/47. ready for road. overall mm (in) 2175 (85.37) Steering head angle in normal-load position ° 64.28) Wheelbase in normal-load position mm (in) 1473 (57.496/32.

4 mm (in) kg (lb) % kg (lb) 9 (0.496/32. front/rear Permitted total weight 46.795) Max. ready for road.33) Width over handlebar. with weights mm (in) 775 (30. overall mm (in) 2230 (87.wheel track offset Unladen weight.28) Wheelbase in normal-load position mm (in) 1485 (58.803) Steering head angle in normal-load position ° 62.496) . full tank Axle load distribution (without rider). heel angle with 85 kg rider ° 46 Max.024) Caster angle in normal-load position mm (in) 122 (4.375) 51/49 490 (1080.4645) Ground clearance in normal-load position mm (in) 153 (6.45) . at right Length.with adjustable seat mm (in) 780/800/820 (30.9 Max. mirrors mm (in) 1380 (54.354) 275 (606.Technical Data R 1100 RT Location of manufacturer’s type plate / frame number On frame. height excl.71/31.512) Width over pillion footrests mm (in) 677 (26.65) Height of seat at unladen weight mm (in) 800 (31.

874) Caster angle in normal-load position mm (in) 115 (4.7796) 1366 (53. ready for road. at right Length. heel angle with 85 kg rider ° 47 47 Max. overall mm (in) 2189 (86.5275) 115 (4.897) 734 (28.4 kg (lb) 450 (992.25) 46.5275) Steering head angle in normal-load position ° 62.6/49.039) 890 (35.07/33.874) 200 (7.7796) Width over handlebar.Technical Data R 850 GS R 1100 GS Location of manufacturer’s type plate / frame number On frame.25) 9 (0. height excl. with weights mm (in) 890 (35.815) % 50.858) 840/860 (33.815) 50.wheel track offset Unladen weight.9 Max. front/rear Permitted total weight mm (in) 9 (0.897) Height of seat at unladen weight mm (in) 840/860 (33.6/49. mirrors mm (in) 1366 (53.18) Max.18) 2189 (86.07/33. full tank Axle load distribution (without rider).4 450 (992.409) Ground clearance in normal-load position mm (in) 200 (7.354) 243 (535.9 62. at right On frame.354) kg (lb) 243 (535.858) Wheelbase in normal-load position mm (in) 1509 (59.5 .039) Width over pillion footrests mm (in) 734 (28.409) 1509 (59.

496) Max.25) 9 (0.175) 50.897) Height of seat at unladen weight mm (in) 760/780/800 760/780/800 Wheelbase in normal-load position mm (in) 1487 (58.175) % 50. overall mm (in) 2197 (86.543) Ground clearance in normal-load position mm (in) 138 (5.96) Width over pillion footrests mm (in) 734 (28. at right Length.433) 138 (5.25) .wheel track offset Unladen weight.354) kg (lb) 235 (518.897) 734 (28. with weights mm (in) 761 (29.9 61. at right On frame.433) Caster angle in normal-load position mm (in) 127 (5) 127 (5) Steering head angle in normal-load position ° 61.1 450 (992.543) 1487 (58.1 kg (lb) 450 (992. ready for road.354) 235 (518. height excl. full tank Axle load distribution (without rider).496) 2197 (86. heel angle with 85 kg rider ° 45 45 Max. front/rear Permitted total weight 46.9/49. mirrors mm (in) 1170 (46.96) 761 (29.062) Width over handlebar.6 mm (in) 9 (0.9 Max.9/49.062) 1170 (46.Technical Data R 850 R R 1100 R Location of manufacturer’s type plate / frame number On frame.

frame RS469010 46.7 .General view.

8 10x 20 0 40 km/h 0000 000 240 220 120140 120 140 160 100 180 80 25 0000 200 60 3 1 2 4 0 5 6 7 9 8 4x 10 2x 2x 2x 4x 1x 3x 4x 3x 6x 4x 4x 4x 3x 2x 2x 2x 2x 4x 2x 2x 2x 3x 2x 2x 2x 2x 2x 2x [RT] General view of fairing sections RT469010 .um 90° gedreht 46.

9 .RT460260 [RT] Removing and installing front mudguard 46.

Install in the reverse order of work. Take off the mirror. With the other hand. then at the rear. Take off small side sections of fairing (1). Offer the mirror at its three mounting points. strike the mirror housing lightly towards the mirror surface (arrow). Remove side sections of fairing (2) and spoiler (3). Strike the mirror housing lightly.10 RT460280 . to engage it 46. first at the front.6x 1 4x 2 4x 2x 3x 3 4x RT460270 [RT] Removing and installing fairing sections • • • • • • Remove dualseat. Hold mirror with one hand.

Pull off plug at headlight. Remove side mirrors. Remove side trim panels. Separate the plug connection and remove the electric drive (3). 46. Remove inner cover for trim. Install in the reverse order of work. Remove windshield (1). Remove bracket (2) for windshield. Detach the aerial. Remove upper section of fairing.11 .4x 1 2 4x 1x 3 3x RT460290 [RT] Removing and installing windshield • • • • • • • • • • • Remove dualseat.

4 5 6 7 8 3 9 2 120140 0 16 100 180 80 25 0000 200 60 220 40 0 00 24 20 000 0 10 1 0 km/h 4x 2x 10x RT460300 [RT] Removing and installing inner fairing panel 46.12 .

1 2 2x RT460310 [RT] Removing and installing upper section of fairing • e Caution: Before installing upper section of fairing. • • • • • • • • Remove dualseat.13 . Remove side trim panels. L Note: Switch off ignition. Remove windshield. push metal bushings (1) on to threaded pins (2). Remove upper section of fairing. Detach the aerial. 46. Insulate ground (earth) lead. Remove inner cover for trim. Pull off plug for headlight. Install in the reverse order of work. Remove side mirrors. Disconnect ground (earth) lead from battery.

. Install in the reverse order of work... Remove trim support bracket. Detach plug strips.. Detach instrument cluster. wiring harness and wires from fairing holder. Remove upper section of fairing.. Remove storage compartment and air intake stub pipe. Remove windshield holder... Remove inner cover for trim. Detach oil cooler mount.. Disconnect ground (earth) lead from battery. • • • • • • • • • • • • Remove dualseat.... Remove side trim panels.14 Do not scratch the mudgard when setting down the oil cooler. Remove side mirrors. 20 Nm .RT460120 [RT] Removing and installing fairing holder L Note: e Caution: • Switch off ignition. 46.. X Tightening torque: Fairing support bracket to frame . Insulate ground (earth) lead... Remove windshield...

15 . Install in the reverse order of work. 46.4x 2x RT460320 [RT] Removing and installing luggage rack/case holder • • • Remove dualseat. Remove luggage rack/case holder.

16 . Remove luggage rack and case holder. Remove small side sections of fairing. L Note: When installing.1 2 3 RT460331 [RT] Removing and installing rear fairing • • • • • • Remove dualseat. Remove rear fairings (1) and (2). note right and left rubber buffers (3). Remove rear light. Install in the reverse order of work. 46.

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

Remove luggage rack and case holder. Remove small side sections of fairing. Remove rear light. • • • • • • • Remove dualseat. Insulate ground (earth) lead. 46. Remove rear trim panel. Disconnect ground (earth) lead from battery.18 . Install in the reverse order of work.2x 2x 2x 2x RT460350 [RT] Removing and installing lower rear section e Caution: Switch off ignition. Remove lower rear section.

................ Remove center stand.. • • • • • • Disconnect tension springs... BMW No. 42 Nm Attach vehicle stand.. Lubricant:. Disconnect plug from side stand switch....g.. [GS] with extension bushes and bolts.. Install in the reverse order of work. e............................ 72 Nm 00 1 520 Carrier plate at engine block.v 2701 2 v 2701 1 2 GS460171 [RT/GS/R] Removing and installing center stand • • [GS] Remove the oil pan protection....... M8 countersunk screw (clean thread + Loctite 2701). 21 Nm R46017 • Side stand to pivot mount (clean thread + Loctite 2701).. Staburags NBU 30 PTM X Tightening torque: Center stand to carrier plate (clean thread + Loctite 2701)..... 46......... Remove left/right pivot bushes (1)........19 . [RT] Remove the fairing spoiler. 21 Nm Carrier plate to engine block.. BMW No.. 00 1 527.... Remove left/right pivot mounts (2). M 12 (clean thread + Loctite 2701)........................ to motorcycle. 00 1 520....

Staburags NBU 30 PTM X Tightening torque: Side stand to pivot mount (clean thread + Loctite 2701)..... Remove side stand.. 1 RS610050 • • Disconnect plug (1) from side stand switch and remove switch.Removing and installing side stand • • Disconnect tension springs.... GS460220 e Caution: Note: correct cable run (arrow...........g...20 . Install in the reverse order of work. e......... 42 Nm 46........ Lubricant:......

.................................. 18 Footrest plate to rear frame M 6 screw ...1 2 RT460360 [RT] Removing and installing left footrest plate • • • • • • • Remove dualseat.. Detach gear shift linkage (1) from footrest plate........ 21 M 10 screw ................................. 42 Nm Nm Nm Nm 46.... Install in the reverse order of work... 6 M 8 screw ............ Remove left side section of fairing.................................................................. Detach power socket retaining bracket (2)..... Remove small left side section of fairing. X Tightening torque: Foot pedal to footrest plate .......... Remove the footrest plate........21 ..

..... Remove the footrest plate......... Release pin on brake linkage.. X Tightening torque: Footrest plate to rear frame M 6 screw . Detach the contact switch (3)... 42 Nm 46. 21 Nm M 10 screw ........................................1 3 2 RT460370 [RT] Removing and installing right footrest plate • • • • • • • • • Remove dualseat.. Install in the reverse order of work.22 ........... Detach brake pedal (2) from footrest plate................. Remove right side section of fairing........ Remove retaining screws for brake master cylinder (1) from footrest plate...... 6 Nm M 8 screw .............. Remove small side section of fairing at right...............................................

....... The screw pin is a press fit in ball thrust bearing: remove complete unit........... 82 Nm Struts to frame (10....9 screw) . 130 Nm Frame to engine .... 20 Nm 46. 120°C...................................... X Tightening torque: Leading link at ball joint (clean thread + Loctite 2701)....... If necessary.. Remove front suspension strut........... L Note: Before removal..... • • • • Detach struts (2) from frame and loosen at engine.... Unscrew pin (1) from engine and remove..... • • • • • • • • Detach brake line from frame/open the lines... Remove the horn... Detach fairing holder from frame........ Detach fixed tubes at fork bridge.. Pull the leading link up and secure it with a strap....... 58 Nm Struts to engine.... heat the bearing point to max... Install in the reverse order of work. Remove frame.. Pull the leading link up and secure with a strap..... 130 Nm Fork bridge to frame (clean thread + Loctite 243)..2 3 1 RT460130 [RT] Removing and installing frame • • • • Remove fuel tank...................23 ............... 58 Nm Fairing support bracket to frame ................ place foam rubber or similar material below fairing panel.. Remove fork bridge... Detach handlebar from fork bridge. Open cable strap (3) for ABS sensor line at fairing holder... Detach ball joint at front of leading link.. e Caution: Fairing section will drop unless held securely.

46.118 in) Allen screw.1 RS460020 [RS] Removing and installing front mudguard L Note: Retaining screw (1) = 3 mm (0.24 .

RS460060 [RS] Removing and installing side sections of fairing 46.25 .

26 .RS460070 [RS] Removing and installing side sections of full fairing 46.

Detach instrument cluster. Remove headlight.1 RS460080 [RS] Removing and installing windshield • • • • • • • • Remove windshield. Install in the reverse order of work.27 . 46. Remove inner fairing cover. Remove bracket (1) for windshield. Detach top section of fairing. Remove front side sections of fairing.

Turn adjusting shaft (1) counterclockwise to unfasten. Remove side sections of fairing. Detach instrument cluster. 46.28 .1 2 RS460090 [RS] Removing and installing adjustable windshield • • • • • • • • • Remove windshield. Detach top section of fairing. Remove bracket (2) for windshield. Remove headlight. Remove inner fairing panel. Install in the reverse order of work.

RS460100 [RS] Removing and installing inner fairing panel 46.29 .

Detach plug connections for flashing turn indicators. Remove fairing. Remove bracket for windshield. Remove headlight. • • • • • • • • • • • Remove windshield. Install in the reverse order of work. Insulate ground (earth) lead. Remove inner fairing panel. Disconnect ground (earth) lead from battery.RS460110 [RS] Removing and installing top section of fairing e Caution: Switch off ignition. Detach instrument cluster. Unscrew and remove windshield adjusting shaft.30 . Detach top section of fairing. 46. Remove side sections of fairing.

. Detach connector strip and wiring harness from fairing holder..RS460120 [RS] Removing and installing fairing holder e Caution: Switch off ignition. • • • • • • • • • Remove side sections of fairing. X Tightening torque: Fairing support bracket to frame . Install in the reverse order of work...... Remove top section of fairing with headlight. Detach oil cooler mount. 20 Nm 46.. Disconnect ground (earth) lead from battery..31 . Separate plug connectors for headlights and indicators. Remove inner fairing panel. Detach instrument cluster...... Turn adjusting shaft counterclockwise to release windshield adjuster.. Insulate ground (earth) lead..

Detach brake line from frame................ Screw the ball joint on handtight at the front of the leading link.......... 46.... Unfasten screw connection between fork bridge and frame......... If necessary.............. Detach front suspension strut at top.......... 47 Nm [GS/R] .. detach ball joint at fork bridge........ 20 Nm ... 31 5 600. • • • [R] Detach oil cooler holder..... [R] Pull headlight holder forwards. Install in the reverse order of work................. • • • • • • • • • Detach ball joint at front of control arm and pull telescopic fork forwards...9 screw) .. 82 Nm Struts to frame (8.......2362 in) Allen key.............8 screw) .... Detach struts (2) from frame and loosen at engine....................... e Caution: Fairing will drop unless held securely..... Unscrew pin (1) from engine and remove...........32 L Note: Screw pin is a press fit in ball thrust bearing: remove complete unit...... [R] Detach handlebar from fork bridge. [RS] Using socket wrench insert with 6 mm (0.......... Remove frame.. place foam rubber or similar material below fairing panel.......... 47 Nm (10..................... [RS/GS] Detach fairing holder at frame.................................. 58 Nm Fairing support bracket to frame ...... 58 Nm Struts to engine [RS] ..................2 31 5 600 RS 1 RS460130 Removing and installing frame • • • Remove fuel tank...................... X Tightening torque: Frame to engine .... BMW No....

..33 ......... 9 Nm 46....................RS460140 [RS] Removing and installing grab handle/case holder X Tightening torque: Grab handle to rear frame .

Install in the reverse order of work. 46. Remove rear light.RS460040 [RS] Removing and installing rear fairing • • • • Remove dualseat.34 . Remove rear fairing panel.

Install in the reverse order of work. 46. Remove number plate bracket.RS460150 [RS] Removing and installing number plate bracket • • • Remove dualseat.35 .

Remove dualseat lock. Remove turn indicator lenses. Insulate ground (earth) lead. Detach wiring harness from lower rear section. Remove number plate bracket. Remove rear fairing.RS460050 [RS] Removing and installing lower rear section e Caution: Switch off ignition. Remove rear light. • • • • • • • • • • Remove dualseat. Install in the reverse order of work. Disconnect/detach turn indicators. Disconnect ground (earth) lead from battery. Remove lower rear section.36 . 46.

................... Insulate ground (earth) lead.... [ABS] Separate the ABS sensor plug and detach the cable. Remove fuel tank. Pull brake cable out of holder/rear section of frame........ Pull brake fluid container out of holder.. Install in the reverse order of work..... [GS/RT] Detach wiring harness at rear section of frame/detach central electrical equipment box only............. [RS/R/RT] Detach wiring harness from left turn indicator to central electrical equipment box/detach central electrical equipment box only. Disconnect the side stand switch plug and detach the cable. [RS/R/RT] Remove lower rear section. ......... Remove fittings... 47 Nm 46.. Disconnect ground (earth) lead from battery................. • • • • • • • • • • • • • Remove dualseat......on left of engine 4. [RT] Detach footrest plates from rear section of frame. [RT] Remove mirrors..... Detach upper suspension strut mount.... on left of gearbox X Tightening torque: Rear section of frame to gearbox/engine .. [GS/RT] Remove luggage rack............ Remove air cleaner box from rear section of frame.. [RS/R/RT] Remove rear fairing... Remove rear section of frame... [RS/R/RT] Remove rear light......... • • • • • • • • • • • Disconnect the neutral switch plug and detach the cable....... Tightening sequence: 1.......... .....37 ..... on right of gearbox 2...... [RT] Remove side sections of fairing. Detach muffler (silencer) from rear section of frame... Disconnect the brake light switch plug and detach the cable. Detach diagnosis plug and cable...RS 1 2 3 4 RS460160 Removing and installing rear section of frame e Caution: Switch off ignition.... Screw connection . on right of engine 3.. ...............

v 2701 2 v 2701 3 v 2701 v 2701 1 1 2 v 2701 2 RS460030 [RS] Removing and installing center stand • Remove lower section of fairing. 46.38 .

BMW No.... M 12 (clean thread + Loctite 2701)..... M 8 countersunk screw (clean thread + Loctite 2701) . 21 Side stand at bearing mount (clean thread + Loctite 2701)..... e...... Lubricant......... Disconnect plug from side stand switch................ Unfasten left/right retaining screws (1)..... Install in the reverse order of work.................. Disconnect tension springs.39 ..... Take out pivot bushes (2) together with M10 screw........... 42 Nm Nm Nm Nm 46...... 72 Carrier plate at engine block. 00 1 520. Staburags NBU 30 PTM X Tightening torque: Center stand to carrier plate (clean thread + Loctite 2701). Remove left/right bearing mount (3).. 21 Carrier plate to engine block...... Remove center stand...00 1 520 RS460170 • • • • • • • • Raise the motorcycle with stand..........g.....

.................RS460180 [RS] Removing and installing rear footrest plate X Tightening torque: Footrest to footrest plate .........40 ............................ 42 Nm Muffler (silencer) to footrest plate . 21 Nm 46... 35 Nm Footrest plate to rear frame .................

....... 37 Nm 46...................................41 ....... 7 Nm Brake pedal to footrest plate . 22 Nm Master cylinder to footrest plate ...............RS460190 [RS/R] Removing and installing front footrest plate X Tightening torque: Footrest plate to gearbox ..........

46.42 .GS460021 [GS/R] Removing and installing front mudguard • Remove front wheel.

GS460091 [GS] Removing and installing windshield 46.43 .

Remove indicators. Install in the reverse order of work. top mudguard. • • • • • 46. headlight insert. • • • • Remove Remove Remove Remove 1 side sections of fairing.44 Remove headlight holder. GS620020 • Detach instrument cluster. pull off cable connector and draw cable through indicator holder. . L Note: Center retaining screw (1) is inside headlight housing.GS460230 [GS] Removing and installing front fairing e Caution: Switch off ignition. Pull front trim section/top cover upwards to remove. windshield. Insulate ground (earth) lead. Remove indicator glasses. Disconnect ground (earth) lead from battery.

• • • • • • • • Remove headlight holder... Remove top mudguard. • • • • • Remove side sections of fairing. Remove trim support bracket....... Disconnect ground (earth) lead from battery.... Pull front section of fairing/top cover upwards to remove. Insulate ground (earth) lead.. Detach oil cooler mount...... Remove indicators. Install in the reverse order of work.. 46... X Tightening torque: Fairing holder to frame . Remove indicator glasses.. Detach wiring harness from trim holder. 20 Nm L Note: Center retaining screw (1) is inside headlight housing.. Detach instrument cluster....45 . Remove windshield.. pull off cable connector and draw cable through indicator holder.... Remove headlight insert...1 GS460121 [GS] Removing and installing fairing holder e Caution: Switch off ignition..

GS460240 [GS] Removing and installing luggage rack 46.46 .

46. [GS] Remove rear light. Remove turn indicators.GS GS460151 [GS/R] Removing and installing number plate bracket • • • • • • Take off rear section of dualseat.47 . [GS] Remove tool box. Install in the reverse order of work. Remove number plate bracket.

Remove wiring harness from rear section. [R] Remove rear fairing. Install in the reverse order of work. [GS] Remove tool box. Disconnect ground (earth) lead from battery. • • • • • • • • Remove dualseat.GS GS460251 [GS/R] Removing and installing rear mudguard e Caution: Switch off ignition. 46. Remove number plate bracket. Disconnect plugs and leads from rear light and indicators.48 . Detach mudguard. Insulate ground (earth) lead.

... 21 Nm 46..............49 ..........GS460181 [GS/R] Removing and installing rear footrest plate X Tightening torque: Footrest plate to rear frame .

.. 22 Nm 46......50 ...................................GS460191 [GS] Removing and installing front footrest plate X Tightening torque: Hydraulic spring adjuster to footrest plate ...

51 .RS460041 [R] Removing and installing rear fairing 46.

Align front wheel parallel with the gauge. simply screw the supports in on the other side.not the tyre. Adjust measuring stops (arrows) until they contact the wheel rim .52 . against left or right side of motorcycle. using depth gauge (3) or ruler. • • • • • Adjust support (1) so that the measuring plane is as close as possible to the wheel centerline. BMW No. Place track alignment gauge. 46. Measure distance between outer edge of gauge and wheel rim. The gauge must slide freely up to the motorcycle. 36 3 920. and make a note of the dimension. Attach hook (2) to wheel spoke to secure the gauge firmly to the wheel. L Note: In order to use the track alignment gauge on either the left or right side.2 36 3 920 3 1 RS460200 Checking running gear Measuring wheel track offset • • Place vehicle on level ground on center stand.

752 in) Fh A + ---2 = 94.53 ..0 (3.614 in) Fh B + ---2 = 93. EXAMPLE: Fv Fh A + ----..• • Calculate wheel track offset S: Wheel track offset S is the distance to left or right between the longitudinal axes of the front and rear wheels.354 in) Fixed value (A) +half rim width L Note: Explanation of measurement: A = 50.72 in) Minus sign = track offset to left Plus sign = track offset to right B Fh B S Measured value (B) +half rim width B = 52..72 in) —93.5 mm (0 059 in) Fh A RS460210 46..66 in) = S Wheel track offset: S A = 1..5 mm (3..66 in) Fixed value (A) —measured value (B) = S 94..– B + ---. 9 mm (0..0 mm (1..0 mm (1.047in) Fv ---2 = 41.9685 in) Fh -----2 = 44.. = S  2 2 Formula Permissible track offset (S): .5 mm (1.5 mm (3.0 mm (2.0 mm (3.

........................................51 Equipment 51 Contents Page Removing and installing ignition switch/steering lock Removing and installing ignition/light switch ...........................................................3 .........................................................................................5 [R] Removing and installing dualseat lock Removing and installing lock barrel ..............................................................................................................................................................................3 Removing and installing lock barrel .5 .................................................................6 [RT] Removing and installing storage compartment lock ................................................6 ....................................................................6 51.3 Drilling out lock barrel .....................................................................1 .5 [GS] Removing and installing dualseat lock Removing and installing lock barrel ............................................................................................................................................4 Drilling out lock barrel ..................................................................5 ....................................3 Removing and installing lock barrel for fuel tank filler cap .............................................................................................4 [RS/RT] Removing and installing dualseat lock Removing and installing lock barrel .....................................................6 [GS] Removing and installing helmet lock ....................................

51.2 .

. drill bit to drill the full length of the lock barrel.3149 in) dia.... Insert the lock barrel with the key in the ON position. BMW No.. drill bit... Pull out the ignition switch/steering lock.3 .0.... Drilling out lock barrel Use a 4-5 mm ( 0. Use an 8 mm (0. Lubricate the new lock barrel with Shell Retinax A..1969 in) dia..1969 in) deep into serrated screw (1). • Removing and installing ignition/light switch 2 GS510030 • Remove socket head cap screw (2). X Tightening torque: Serrated screws (thread cleaned + Loctite 270).51 Removing and installing ignition switch/steering lock Removing and installing lock barrel 1 1 v 270 • • • • • • GS510020 RS510010 Remove fork bridge.157 in) dia. 51 0 510. 51.. drill bit to drill away the screw head. • Repeat with a drill bit of larger diameter until the lock barrel can be removed. drill about 5 mm (0... With a 4 mm (0... Press lock barrel down until keeper engages.. Install steering lock with serrated-screw socket wrench insert... 15 Nm • • • • • Key in ON position/press in keeper (1) with a stiff wire or similar. Unscrew and remove stud bolt with stud bolt extractor.. Pull out lock barrel with key.157 .

0. Drilling out lock barrel • Drill out entire length of lock barrel with a 4-5 mm ( 0.2 1 GS510040 Removing and installing lock barrel for fuel tank filler cap L Caution: Prevent screws from falling into fuel tank: cover fuel tank filler neck with cloth.4 .1969 in) dia. Install in the reverse order of work. Grease new lock barrel with Shell Retinax A. twist drill bit. Insert key in lock barrel and press down on retainer (2). • • • • • • Open cap/remove lower part of cap (1). Pull out lock barrel with key. • Repeat with a larger diameter drill bit until the lock barrel can be removed.157 . 51. Install lock barrel with key (at a right angle to direction of travel).

51. Remove dualseat lock.5 . Insert lock barrel until retainer engages.[RS/RT] Removing and installing dualseat lock [GS] Removing and installing dualseat lock RS510051 GS510060 Removing and installing lock barrel Removing and installing lock barrel • • • • • • • Press down retainer (arrow) with a piece of wire or similar. GS510070 • • • • Press the locating tongue (arrow) of the lock barrel in the housing and pull the lock barrel out with the key. Install in the reverse order of work. Insert lock barrel until retainer engages. Lubricate the new lock barrel with Shell Retinax A. Pull out lock barrel with key. Dismantle key side of dualseat lock (2 screws) and open up carefully. Remove luggage rack. Lubricate the new lock barrel with Shell Retinax A.

Install in the reverse order of work.[R] Removing and installing dualseat lock [RT] Removing and installing storage compartment lock 1 RS510090 Removing and installing lock barrel • • • • Press down retainer (arrow) with a piece of wire or similar. Press the locking section back on and press in the safety peg. Pull out lock barrel with key. Take off the locking section (1). Pull out lock barrel with key. Press retaining lug on lock barrel down into housing and remove lock barrel with key. Press the retaining lug into the lock barrel and insert until the detent engages. Insert lock barrel until retainer engages. Remove helmet lock. Insert lock barrel until retainer engages. Remove spring and retaining hook. Use screwdriver to lever out inside cover. Lubricate the new lock barrel with Shell Retinax A. 51. Lubricate the new lock barrel with Shell Retinax A. [GS] Removing and installing helmet lock GS510080 • • • • • • • • Open retaining bracket. Lubricate the new lock barrel with Shell Retinax A.6 RT510100 • • • • • • Press in safety peg (arrow) with a piece of wire or similar. .

................................5 52................................3 [RS] Dismantling and assembling dualseat ....................................................1 ..........4 [GS/R] Dismantling and assembling dualseat ...................................................................52 Seat 52 Contents Page [RT] Dismantling and assembling dualseat .....

2 .52.

3 .52 RS520013 [RT] Dismantling and assembling dualseat 52.

RS520011 [RS] Dismantling and assembling dualseat 52.4 .

5 .GS RS520020 R RS520013 [GS/R] Dismantling and assembling dualseat 52.

...............12 [RT] Wiring harness View from right ..............................................................................................................................................28 [RS] Wiring harness at right switch unit [GS] Wiring harness View from left .....................................................................................................................................................................................................................................................................................................................................................................................20 .............................................29 .......................................................................................10 .......................................9 Installing wiring harness/connections in central electrical equipment box Installing wiring harness in central electrical equipment box/output [RT] Wiring harness View from left ..........................................7 Dismantling/assembling central electrical equipment box .....................................34 Removing and installing battery holder ................................. 3 Removing and installing central electrical equipment box .....37 61........................................................................................................................................................61 General electrical equipment 61 Contents Page Technical Data ................................................1 ..............11 ...........8 Connections to fuses: [RS/GS/R] ............................................................................................................................................................................................16 [RT] Wiring harness at fairing holder .......................................................19 [RT] Wiring harness at instrument cluster [RS] Wiring harness View from left .............................................................25 [RS] Wiring harness at left switch unit ...................................................8 Frame wiring harness [ABS] ..............................8 Connections to fuses: [RT] ......30 [GS] Wiring harness View from right ........................................................7 Relay positions (central electrical equipment box) ...21 [RS] Wiring harness View from right ..........

61.2 .

3 .61 Technical Data Battery R 1100 RS Ah 19 61.

Technical Data Battery 61.4 R 1100 RT Ah 19 .

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

6 R 850 R Ah 19 R 1100 R 19 .Technical Data Battery 61.

detach complete wiring harness and remove it with the fuse box. • See detail drawing (3).4 in). or remove the relays and relay bases. shorten the rubber tag on the splash guard mount (arrow) to 10 mm (0. If necessary.3 1 2 RS610062 Removing and installing central electrical equipment box e Caution: • • • Take out retaining screws (2) for lower section of central electrical equipment box. • • • • Dismantling/assembling central electrical equipment box • • • • Remove dualseat. Disconnect ground (earth) lead from battery. [RS/R/RT] Take off rear fairing at left and right. After assembly. Install in the reverse order of work. [RT] Remove lower rear section.7 . [RT] Remove luggage rack/case holder. Take out retaining screws (1) for upper section of central electrical equipment box. 61. Remove cable tray. [RT] Remove small side fairing sections at left and right. Insulate ground (earth) lead. Switch off ignition.

.......... 15 6.............. Motronic relay 8....... Heated handlebar grips ............ 15 9................... Encoding plug for Motronic and catalytic converter 2................................... 15 3.............. Heated handlebar grips.......................... 4 8......... 4 8........ Fuel pump ............. Spare fuse.. 15 10........................... Starter motor relay 4... Fuel pump relay 7............................ Fuel pump ......... Instrument cluster...... 1 on left. ABS warning relay 9.................................... 4 9.......................... 1 on left......... Flashing turn indicators.. Motronic.. brake and rear lights .... Flashing turn indicators.... 15 7................... 15 7...... Spare fuse......... Motronic........ 15 3..Fuse Connections to fuses: [RS/GS/R] (No...... brake and rear lights ...... Instrument cluster.... Load-relief relay 5............ 15 10....................................................... 15 5............................................................ Radio ..... clock................................................Spare fuse.. 15 5................................. Parking light .....Spare fuse........................ 15 2...... looking forwards) 1............. 15 4.................. Power socket . Horn relay 6........................ Not in use 10............. 15 6.... 4 Amp Amp Amp Amp Amp Amp Amp Amp Amp Amp .................. looking forwards) 1...... Power socket .............. Parking light .............. 15 4............3 1 8 9 7 6 4 5 10 2 11 RS610070 Relay positions (central electrical equipment box) 1... 15 2...... Fuel gauge/display damping 3............. clock ........Flasher unit 11.8 Amp Amp Amp Amp Amp Amp Amp Amp Amp Amp Connections to fuses: [RT] (No. 15 61..... Spare fuse....

. CENTOPLEX 3 CU to the central earth (ground) point...Frame wiring harness [ABS] e Caution: Threaded earth (ground) connection at engine: use galvanized (yellow) screws....9 . e. fit the central electrical equipment box first. Run wiring without kinking and avoid risk of abrasion.. When installing... Screws with unsuitable corrosion proofing can cause the electrical resistance to rise as high as 80 Ω. X Tightening torque: Ground (earth) connection to engine . 10 Nm 61. Note the number and position of the cable straps. which must be cleaned to bright metal first. take out the central electrical equipment box at the same time. L Note: When removing the wiring harness...g. • Apply a thin coating of contact grease.

10 .RS610090 Installing wiring harness/connections in central electrical equipment box 61.

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

[RT] Wiring harness View from left 1 2 3 RT610160 61.12 .

13 .1 RT610161 61.

2 RT610162 61.14 .

3 RT610163 61.15 .

[RT] Wiring harness View from right 1 2 RS610170 61.16 .

1 RT610171 61.17 .

18 .2 RT610172 61.

19 .RT610180 [RT] Wiring harness at fairing holder 61.

RT610190 [RT] Wiring harness at instrument cluster 61.20 .

21 .[RS] Wiring harness View from left 1 2 3 RS610040 61.

1 RS610041 61.22 .

2 RS610042 61.23 .

3 RS610043 61.24 .

25 .[RS] Wiring harness View from right 1 2 RS610030 61.

26 .1 RS610031 61.

27 .2 RS610032 61.

28 .RS610120 [RS] Wiring harness at left switch unit 61.

29 .RS610130 [RS] Wiring harness at right switch unit 61.

[GS] Wiring harness View from left 1 2 3 GS610140 61.30 .

1 GS610141 61.31 .

32 .2 GS610142 61.

3 GS610143 61.33 .

34 .[GS] Wiring harness View from right 1 2 GS610150 61.

1 GS610151 61.35 .

36 .2 GS610152 61.

Remove battery.. then negative terminal.Removing and installing battery holder RS610010 • • Remove fuel tank.37 . Reconnect positive battery terminal first. e Caution: Disconnect negative battery terminal first. En caso necesario. [ABS] Remove control unit. 61. Install in the reverse order of work. then positive terminal. • • • • • Remove Motronic control unit. soltar el distribuidor de los cables de mando Remove the battery holder.

......................8 [RS] Dismantling and assembling instrument cluster [GS] Removing and installing instrument cluster .....................9 [GS] Dismantling and assembling instrument cluster [R] Removing and installing instrument cluster ...........................................................................1 .....................10 62.........................................................7 . 3 [RT] Removing and installing instrument cluster .....62 62 Instruments Contents Page Technical Data .............................9 ...........................................................................................................................................................................7 [RT] Dismantling and assembling instrument cluster [RS] Removing and installing instrument cluster .............................................................................8 ........

2 .62.

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 1.6 62.7 W Speedometer drive Speedometer drive ratio I = 2.3 .

Technical Data R 1100 RT Instrument cluster Telltales for turn indicators/high beam A 14 V 3 W Instrument lighting / telltales A 12 V 1.6 .7 W Speedometer drive Speedometer drive ratio 62.4 I = 2.

Technical Data R 850 GS R 1100 GS 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 1.0 Instrument cluster Speedometer drive Speedometer drive ratio 62.0 I = 3.5 .7 W I = 3.

0 I = 3.6 I = 2.7 W Instrument cluster Speedometer drive Speedometer drive ratio 62.Technical Data R 850 R R 1100 R Telltales for turn indicators/high beam A 14 V 3 W A 14 V 3 W Instrument lighting / telltales A 12 V 1.6 Spoked wheel I = 3.0 .7 W A 12 V 1.6 Cast wheel I = 2.

7 . • • • • Unscrew threaded connections at instruments (2). Disconnect plugs. Remove mirrors. Remove upper section of fairing. Assemble in the reverse order of work. Pull off instrument lighting. Remove side sections of fairing. Detach trip distance recorder reset shaft (3) from speedometer. Detach speedometer shaft. Remove monitor unit (4). Install in the reverse order of work. Remove windshield. Remove inner fairing panel.3 4 1 2 RT620050 [RT] Removing and installing instrument cluster [RT] Dismantling and assembling instrument cluster • • • • • • • • • • • Remove dualseat. Detach instrument cluster (1) and lift out of mount. 62.

Detach instrument cluster (1) and pull up away from mount. Assemble in the reverse order of work. . Pull off instrument lighting.. Remove monitor unit (3). e Caution: When installing the speedometer. Disconnect plugs. [Windshield adjustment] Turn windshield adjuster shaft to left/detach.3 1 2 RS620011 [RS] Removing and installing instrument cluster [RS] Dismantling and assembling instrument cluster • • • • • • • Remove inner cover for trim. note the grommet on the trip distance recorder reset button.8 • • • Unscrew threaded connections at instruments (2). Detach speedometer shaft. Install in the reverse order of work. 62.

Disconnect plugs. Detach speedometer shaft.9 . Pull off instrument lighting. Remove telltales. Assemble in the reverse order of work. • • • • Unscrew threaded connections (3) at instrument cluster. Install in the reverse order of work. 1 G62002 • • • • • • Remove headlight housing/detach instrument cluster mount on inside of headlight housing (1).2 2 3 3 3 3 4 4 GS620030 [GS] Removing and installing instrument cluster [GS] Dismantling and assembling instrument cluster • • Remove windshield. Remove left cover. Detach instrument cluster (2). 62. Remove monitor unit (4).

Remove upper trim (5) from instrument cluster. Assemble in the reverse order of work. Remove left (3) and right trims from instrument cluster. Detach cable strap at headlight. Remove headlight holder (6). Remove speedometer (4). Remove handlebar. Remove speedometer reset extension (7). Pull off instrument lighting and telltales.6 3 1 2 4 5 7 RS620040 [R] Removing and installing instrument cluster • • • • • • • • • • • Remove headlight mount (1) and adjuster (2).10 . Remove indicators. 62.

............................................................................................................7 [RS] Removing and installing headlight .............................................................................1 ......................................................................................................................................... 3 [RT] Removing and installing headlight .................10 [GS] Removing and installing front flashing turn indicator [R] Removing and installing headlight .......................63 63 Lights Contents Page Technica Data ..............................................................................................................................................................10 63..8 [GS] Removing and installing headlight ................................................................................................................9 Adjusting headlight ........................10 Adjusting headlight .................................................................................................................................................................................7 Adjusting headlight ...........................................8 Adjusting headlight ..............................10 .....................................

63.2 .

with halogen bulb and manual beam throw adjustment Bulbs High beam/low beam H 4.63 Technica Data R 1100 RS Headlight rectangular. 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 63. 55/60 W halogen.3 .

Technica Data R 1100 RT Headlight rectangular.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 63. with halogen bulb Bulbs High beam/low beam H 4.

55/60 W halogen. 55/60 W halogen. with halogen bulb High beam/low beam H 4.Technica Data R 850 GS R 1100 GS Headlight rectangular. asymmetric H 4. with halogen bulb rectangular. 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 Bulbs 63.5 .

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 Bulbs 63.Technica Data R 850 R R 1100 R Headlight circular. asymmetric H 4. 55/60 W halogen.6 . with halogen High beam/low beam H 4. with halogen circular. 55/60 W halogen.

. Remove side trim. e Caution: Do not touch inner surface of reflector or bulbs with bare hands...... Pull off plug at headlight. Remove upper section of fairing..... Install in the reverse order of work........... • • • • • • • • • • 3 Remove dualseat....91 in) at a distance of 10 m (32. Detach windshield.... -15 cm (5... Counter-clockwise rotation: .. Remove headlight.. 63. Disconnect ground (earth) lead from battery. Remove headlight retaining screws (arrows). Correct the headlight beam throw with adjusting screw (2)...... Remove mirrors........ Insulate ground (earth) lead. longer Clockwise rotation: . 2 1 RT630020 • • Move swivel lever (1) to top position.7 . Remove inner cover for trim...............shorter Adjustment distance: .....81 ft) • Adjust side angle with adjusting screw (3).RT630060 [RT] Removing and installing headlight Adjusting headlight e Caution: Switch off ignition..

. Install in the reverse order of work... Detach windshield. -15 cm (5.. • • • • • • • • • • 3 Remove side trim.. Remove headlight.. Insulate ground (earth) lead............. Disconnect ground (earth) lead from battery...... Detach headlight at front section of fairing..shorter Adjustment distance: ... longer Clockwise rotation: . Counter-clockwise rotation: .....8 1 Adjust side angle with adjusting screw (3)..91 in) at a distance of 10 m (32......... 2 RT630020 • • Move swivel lever (1) to top position.... Correct headlight beam throw with adjusting screw (2)..... Detach front section of trim. Detach windshield holder at headlight.81 ft) • 63.... . Detach instrument bracket... Detach headlight at fairing holder.... Remove inner cover for trim.. e Caution: Do not touch inner surface of reflector or bulbs with bare hands.RS630010 [RS] Removing and installing headlight Adjusting headlight e Caution: Switch off ignition.......

RS630030 [GS] Removing and installing headlight e Caution: Switch off ignition. Insulate ground (earth) lead.9 . Remove headlight housing. Remove headlight insert. • Detach instrument cluster. • • Unfasten headlight beam throw adjuster. L Note: The center retaining screw (1) is in the headlight housing. • • 1 Remove windshield. 63. e Caution: GS620020 Do not touch inner surface of reflector or bulbs with bare hands. Disconnect ground (earth) lead from battery.

.85 in) at a distance of 10 m (32.81 ft) . pull cable connector off reflector and pull cable through indicator holder.81 ft) • Tighten locknut firmly. e Caution: Do not touch inner surface of reflector or bulbs with bare hands. Remove indicators. L Note: Wrench size = 6 mm (0. Insulate ground (earth) lead... GS630040 • • Unscrew locknut on adjusting linkage (arrow). Install in the reverse order of work. RS630050 Adjusting headlight Disconnect ground (earth) lead from battery. Adjustment distance .. Correct vertical beam throw with adjusting linkage. Insulate ground (earth) lead. • • • • • Procedure: same as for removing headlight.Adjusting headlight [R] Removing and installing headlight e Caution: Switch off ignition. Remove headlight holder Remove indicator lenses.24 in) e Caution: Do not touch inner surface of reflector or bulbs with bare hands.. [GS] Removing and installing front flashing turn indicator e Caution: Switch off ignition. • • • Remove turn indicator holder. -25 cm (9. Disconnect ground (earth) lead from battery.85 in) at a distance of 10 m (32. Correct beam throw with the adjusting linkage (arrow). Beam throw can be adjusted within the limited rapid resetting range by tilting the headlight upwards or downwards. -25 cm (9.10 Adjustment distance: ... 63..

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