BMW R1100 - 850 Service manual [UK]

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

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, Dis-

assembly, Repair, Assembly, Installation.

● The entire contents are divided into individual chapters, corresponding to the Construction Groups.

11 . 10

Chap. Page number within chapter

● Work to be performed during an Inspection is described in Group “00”. The various inspection routines

are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that work can take place without interruption.

● Use of the BMW special tools needed for certain tasks is described in the work instructions.

If the need arises, repair instructions are also issued in the form of Service Information. This information is of course incorporated into the next issue of the repair manual. We also recommend you to consult the detailed illustrations on the Parts microfiches as an additional source of information.

BMW Motorcycle After Sales

Published by: BMW Motorrad

Hufelandstr. 6 D - 80937 München

All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission. Errors and omissions excepted; subject to technical amendment. Produced in Germany

<< 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

Group / Chapter

34 Brakes

36 Wheels and tyres

46 Frame

51 Equipment

52 Seat

>> Continuation

61 General electrical equipment

62 Instruments

63 Lights

<< Back

BMW AG Motorcycle Division Maintenance Schedule R1100RT/R 1100RS/R850GS/R1100 GS/R 850R/R 1100 R

Customer Registration No.

Order No. Signature of mechanic

BMW Inspection

1000 km/ 600 mls

BMW Service

10 000 km/6000 mls

BMW Inspection

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

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

for short-distance driving or outside temperatures below 0°C every 3 months, every 3,000 km (1,800 miles) at the latest

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

normally every 40,000 km (24,000 miles), but if fuel is of poor quality every 20,000 km (12,000 miles)

Renew Poly-V-belt every 40,000 km (24,000 miles)

After 60,000 km (36,000 miles), change the maintainance free Poly-V-belt, do not adjust

invoiced as a separate item

)

20 000 km/12 000 mls

BMW

Annual Service

Order No. 01 71 7 654 296 UX-VS-2, 03.99 Printed in Germany

BMW AG Motorcycle Division Pre-delivery check R1100 RT/R 1100 RS/R850GS/R1100 GS/R 850R/R1100 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 Measuring unit or

specification

Oilcapacities

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

3.75

5.50

Brand-name HD oil for

petrol engines of API classi-

fication SE, SF, SG;

combination with CC or CD

litre litre

[SI 11 048 90]

specification

Gearbox

Rear wheel drive

Valve clearance

measured cold, i.e. at max. 35 °C

Ignition

Static ignition

Spark plugs

Electrode gap limit of wear

Engine idle speed 1000 +150 1/min CO value (without catalytic converter) 1.5 ±0.5 Vol % Cable adjustment

for increased cold starting speed (without cable junction)

(with cable junction)

throttle (without cable junction)

gas cable (one piece) connecting cable

throttle (with cable junction)

gas cable (one piece) junction cable

Clutch cable adjustment

wire cable at handle bar lever at lever

Tyre pressure

depending on load and speed

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 Printed in Germany

fresh fill 1.0 change 0.8

fresh fill 0.25 change 0.23

E 0.15 / A 0.30 mm

disconnect at

6° b TDC

Bosch FR5DTC

0.8

1.0

< 1

no backslash

ca. 0.5

no backslash

ca. 0.5

no backslash

12.0

7.0

front: 2.2 – 2.5

rear: 2.5 – 2.9

11 32 23 23

8 8

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

Nm (clean thread) Nm (clean thread) Nm (clean thread)

Nm (8.8 screw)

° Torsion angle

litre litre

mm mm

mm play

mm thread

mm play

bar bar

Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm

Nm Nm

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

Operating materials ...................................................................................................................21

Key to maintenance intervals ...................................................................................................22

Change engine oil, renew oil filter element .................................................................22

(Inspection I, II, III, IV) ........................................................................................................................22

Change the oil in the gearbox and rear wheel drive ...............................................23

(Inspection I, III, IV) ............................................................................................................................23

Changing oil in gearbox .............................................................................................................23

Changing oil in rear wheel drive .............................................................................................23

Checking battery acid level/topping up if necessary, cleaning/greasing

battery posts .................................................................................................................................24

(Inspection III, IV) ...............................................................................................................................24

Renewing air cleaner ...............................................................................................................24

(Inspection III) ....................................................................................................................................24

Renewing fuel filter ...................................................................................................................25

(Inspektion III) ....................................................................................................................................25

Checking/renewing spark plugs ........................................................................................29

(Inspection II, III) ................................................................................................................................29

Taking up slack at cylinder heads ....................................................................................29

(Inspection I) ......................................................................................................................................29

Checking/adjusting valve operating clearances ......................................................30

(Inspection I, II, III) .............................................................................................................................30

Adjusting Poly-V belt ................................................................................................................31

(Inspection I, II, III) .............................................................................................................................31

Renewing Poly-V belt

(40 000 km/24 000miles) ..........................................................................................................31

(renew maintenance-free belts every 60 000 km/36 000 miles) .........................................................31

Checking brake pads and discs for wear/renewing ...............................................32

(Inspection III) ....................................................................................................................................32

(ABS: Inspection II, III) .......................................................................................................................32

00.1

Contents Page

Checking brake pads for wear ................................................................................................32

Renewing brake pads – front brake ......................................................................................32

[RS] Renewing brake pads - rear brake ..............................................................................33

[GS/R/RT] Renewing brake pads - rear brake .................................................................33

Checking brake discs for wear ...............................................................................................33

Checking brake fluid level/topping up ............................................................................33

(Inspection III) ....................................................................................................................................33

Bleeding/renewing the brake fluid using the handbrake lever/

brake pedaln .................................................................................................................................34

(Inspection III, IV) ...............................................................................................................................34

Bleeding front brake circuit/renewing fluid ........................................................................34

Bleeding rear brake circuit/renewing brake fluid ............................................................34

Grease the centre stand [RS], side stand and clutch cable nipple ................35

(Inspection II, III, IV) ...........................................................................................................................35

[RS] Cleaning and greasing the windshield adjusting shaft ...............................35

(Inspection III) ....................................................................................................................................35

[RS] Grease front suspension strut at its lower attachment lug (version with plain bearing only)

(Inspection II, III) ................................................................................................................................35

........................................................................................35

Checking/adjusting clutch operating clearance ......................................................36

(Inspection I, II, III) .............................................................................................................................36

Checking tightness of rear wheel studs ........................................................................37

(Inspection I) ......................................................................................................................................37

[RS] Check tightness of screws at adjustable handlebar ....................................37

(Inspection I) ......................................................................................................................................37

[R] Check steering damper ...................................................................................................37

(Inspection II, III) ................................................................................................................................37

Taking up slack on hose clips at intake stub pipen ................................................37

(Inspection I, III) .................................................................................................................................37

Checking front wheel bearings/

checking tilt play at rear wheel ..........................................................................................37

(Inspection III) ....................................................................................................................................37

Checking swinging arm bearings, adjusting if necessary ...................................37

(Inspection I, II, III) .............................................................................................................................37

Checking/adjusting throttle synchronisation and CO emission value ..........38

(Inspection I, II, III, IV) ........................................................................................................................38

Final inspection with road safety and functional check .......................................42

(Inspection I, II, III, IV) ........................................................................................................................42

00.2

Tightening torques R 1100 RS / R 1100 RT

Model R 1100 RS R 1100 RT

11 Engine

Connection Nm Nm Cylinder head

Tightening sequence:

1. Tighten cylinder head nuts (oiled) crosswise 20 20

1.1 Tighten all nuts to correct torque for joint

1.2 Tighten all nuts to correct angle 90°

1.3 Tighten all nuts to correct angle 90°

2. M 10 screw 40 40

3. M 6 screw 9 9 After 1000 km, tighten cylinder head nuts crosswise:

1. Unfasten one nut

2. Tighten one nut to initial value 20 20

3. Tighten nut to wrench angle 180°

4. Unfasten/retighten M10 screw 40 40 Bearing cap on rocker shaft 15 15 Locknut on valve clearance adjusting screw 8 8 Cylinder head cover to cylinder head 8 8 Camshaft end cover to cylinder head 9 9 Air intake connection to cylinder head 9 9

Camshaft

Chain sprocket to camshaft 65 65 Camshaft bearing cap 15 15

Rotary breather

Vent line to alternator mount cover M 8 screw 20 20 Banjo screw 25 25

Alternator mount cover

M 6 screw 9 9 M 8 screw 20 20

Auxiliary shaft

Chain sprocket to crankshaft 10 10 Chainwheel to auxiliary shaft 70 70 Chain tensioner housing to engine block 9 9

00.3

Model R 1100 RS R 1100 RT

11 Engine

Connection Nm Nm Oil filter

Oil filter 11 11 Oil drain plug 32 32

Oil pump

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

Oil cooler pipe to engine block 10 10 Cooling oil line - banjo screw 25 25 Cooling oil line - 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

Oil cooler hose at oil thermostat – 40

Cylinders

Tightening sequence M 8 screw 20 20 M 6 screw 9 9 Chain guide rail pivot screw 18 18

Timing chain

Chain tensioner 32 32

Connecting rod

Big end cap Joint torque 20 20

Additional wrench angle 80°

Crankcase

35 35 Clean threads and apply Loctite 603 to inner and

outer threads and in the contact face area

Tightening sequence: M 10 screw (oiled) 45 45 M 8 screw (oiled) 20 20 M 6 screw 9 9

00.4

Model R 1100 RS R 1100 RT

12 Engine electrical system

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

13 Fuel preparation and control

Temperature sensor on engine block 25 25

16 Fuel tank and lines

Fuel tank to rear frame 22 22 Fuel pump assembly to tank 6 6

18 Exhaust system

Muffler to footrest 35 35 Manifold to cylinder head (with strap) 22 22

(with jacket pipe) 18 18 Muffler to support plate for center stand 20 20 Clip on muffler 50 50

Grease clamping face with Never Seez

Oxygen sensor (lambda probe) to muffler 55 55

Grease with Never Seez

00.5

Model R 1100 RS R 1100 RT

21 Clutch

Connection Nm Nm

Clutch housing Joint torque 40 40

oil screw threads lightly

Additional wrench angle 32° Housing cover 18 18 Locknut on release lever 22 22

23 Gearbox

Oil filler plug 23 23 Oil drain plug 23 23 Gearbox cover to gearbox housing 9 9 Screw for neutral detent 13 13

clean thread + Loctite 243

Oil guide plate at gearbox housing 9 9

clean thread + Loctite 573, also apply Loctite 573 to sealing face between oil baffle plate and gear-

box housing Gearbox to engine block 22 22 Clutch lever to gearbox housing 18 18 Selector lever to selector shaft 9 9 Pedal to footrest plate 35 18

00.6

Model R 1100 RS R 1100 RT

31 Front fork

Connection Nm Nm

Clamp between fixed tubes and fork bridge 22 – Screw connection between fixed tube and

fork bridge Control arm to ball joint 130 130

Fork bridge to ball joint 130 –

– 45 (free from oil and

grease)

clean thread + Loctite 2701

clean threads + Loctite 2701

Threaded journal to frame – 130

– clean threads

Ball joint to fork slider tube bridge 230 230

Frame 230 –

Slider tube bridge to slider tube 22 –

clean thread + Loctite 243

Screw plug to fixed fork tube 18 pressed fit,

Clamping screws, quick-release axle 22 22 Control arm to engine right 73 73 Screw cap left 42 42

apply light coat of Never Seez to thread Spring strut to frame 47 47 Spring strut to control arm 43

8.8 screw

–

+ Loctite 243

–

do not release

8.8 screw

10.9 screw

32 Steering

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

10.9 screw

–

00.7

Model R 1100 RS R 1100 RT

33 Rear wheel drive

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, input bevel gear 200 200

clean thread + Loctite 273 Housing cover 35 35 Fixed bearing journal

Swinging arm to gearbox/ Swinging arm at rear wheel drive

Free bearing journal

Swinging arm to gearbox/ Swinging arm at rear wheel drive

Locknut on free bearing journal 105 105

Strut at rear wheel drive / gearbox 43 43

Spring strut to rear frame / rear swinging arm

Hydraulic spring adjuster at footrest plate – 22

150 150

clean thread + Loctite 2701

load motorcycle with approx. 85 kg and tighten

loose strut

8.8 screw

10.9 screw

8.8 screw 50

10.9 screw

00.8

Model R 1100 RS R 1100 RT

34 Brakes

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

clean thread + Loctite 273

Brake hose to brake caliper, 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 nec-

essary ABS sensor 4 (handtight) 4 (handtight) ABS unit to holder M6 screw 9 9 M6 screw (Torx) 5 5 Brake line to ABS unit 15 15 Bleed screw to ABS unit 9 9

36 Wheels and tyres

Clamping screws, quick-release axle 22 22 Screw connection, quick-release axle 30 30 Screw on wheel nuts handtight, then tighten

crosswise: Initial tightening 50

Final tightening

105

00.9

Model R 1100 RS R 1100 RT

46 Frame

Connection Nm Nm

Rear frame to gearbox/engine 47 47 Screw connection on right of gearbo at right of engine at left of engine at left of gearbox Footrest plate to gearbox 22 22 Frame to engine 82 82 Struts to frame 47

8.8 screw 58

10.9 screw Struts to engine 47 47 Guard hoop to cylinder head 20 20 Side stand to pivot mount 42 42

clean thread + Loctite 2701

Center stand to carrier plate 21 21

clean thread + Loctite 2701

Carrier plate for center stand to engine block

M12 screw 72 72

clean thread + Loctite 2701

M 8 screw (countersunk) 21 21

clean thread + Loctite 2701 Grab handle to rear frame 9 9 Lifting handle to rear frame 10 10 Footrest plate to rear frame

8.8 screw 58

10.9 screw

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

00.10

Model R 1100 RS R 1100 RT

51 Equipment

Connection Nm Nm

Ignition/steering lock to fork bridg 15 15

61 General electrical system

Horn to horn bracket 8 20 Ground (earth) strap to engine block 10 10 Rubber bushing for battery holder at gearbox 4 4

00.11

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

Model R 850/1100 GS R850/1100R

11 Engine

Connection Nm Nm Cylinder head

Tightening sequence:

1. Tighten cylinder head nuts (oiled) crosswise 20 20

1.1 Tighten all nuts to correct torque for joint

1.2 Tighten all nuts to correct angle 90°

1.3 Tighten all nuts to correct angle 90°

2. M 10 screw 40 40

3. M 6 screw 9 9 After 1000 km, tighten cylinder head nuts crosswise:

1. Unfasten one nut

2. Tighten one nut to initial value 20 20

3. Tighten nut to wrench angle 180°

Camshaft

Chain sprocket to camshaft 65 65 Camshaft bearing cap 15 15

Rotary breather

Vent line to alternator mount cover M 8 screw 20 20 Banjo screw 25 25

Alternator mount cover

M 6 screw 9 9 M 8 screw 20 20

Auxiliary shaft

Chain sprocket to crankshaft 10 10 Chainwheel to auxiliary shaft 70 70 Chain tensioner housing to engine block 9 9

00.12

Model R 850/1100 GS R850/1100R

11 Engine

Connection Nm Nm Oil filter

Oil filter 11 11 Oil drain plug 32 32

Oil pump

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

Oil cooler pipe to engine block 10 10 Cooling oil line - banjo screw 25 25 Cooling oil line - 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

Cylinders

Tightening sequence:

1. M 8 screw 20 20

2. M 6 screw 9 9

3. Chain guide rail pivot screw 18 18

Timing chain

Chain tensioner 32 32

Connecting rod

Big end cap Joint torque 20 20

Additional wrench angle 80°

Crankcase

Tightening sequence:

1. M 10 screw (oiled) 45 45

35 35 Clean threads and apply Loctite 603 to inner and

outer threads and in the contact face area

2. M 8 screw (oiled) 20 20

3. M 6 screw 9 9

00.13

Model R 850/1100 GS R850/1100R

12 Engine electrical system

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

13 Fuel preparation and control

Temperature sensor on engine block 25 25

16 Fuel tank and line

Fuel tank to rear frame 22 22 Fuel pump assembly to tank 6 6 Strut to tank – 15

18 Exhaust system

Muffler to rear frame 24 24 Manifold to cylinder head (with strap) 22 22

(with jacket pipe) 18 18 Muffler to support plate for center stand 20 20 Clip on muffler 50 50

Grease clamping face with Never Seez

Oxygen sensor (lambda probe) to muffler 55 55

Grease with Never Seez

00.14

Model R 850/1100 GS R850/1100R

21 Clutch

Connection Nm Nm

Clutch housing Joint torque 40 40

oil screw threads lightly

Additional wrench angle 32° Housing cover 18 18 Locknut on release lever 22 22

23 Gearbox

Oil filler plug 23 23 Oil drain plug 23 23 Gearbox cover to gearbox housing 9 9 Screw for neutral detent 13 13

clean thread + Loctite 243

Oil guide plate at gearbox housing 9 9

clean thread + Loctite 573, also apply Loctite 573 to sealing face between oil baffle plate and gear-

box housing Gearbox to engine block 22 22 Clutch lever to gearbox housing 18 18 Selector lever to selector shaft 9 9 Pedal to footrest plate 35 35

00.15

Model R 850/1100 GS R850/1100R

31 Front fork

Connection Nm Nm

Screw connection between fixed tube and fork bridge

Control arm to ball joint 130 130

Threaded journal to frame 130 130

Ball joint to fork slider tube bridge 230 230 Slider tube bridge to slider tube 22 22

Screw plug to fixed fork tube press fit, do not release! Clamping screws, quick-release axle 22 22 Control arm to engine right 73 73 Screw cap left 42 42

Spring strut to frame 47 47 Spring strut to control arm 50

Steering damper to fork slider bridge mount – 20

Steering damper mount to fork slider bridge – 9

45 (free from oil and grease)

clean thread + Loctite 2701

clean threads + Loctite 243

apply light coat of Never Seez to thread

10.9 screw

45 (free from oil and grease)

10.9 screw

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

00.16

Model R 850/1100 GS R850/1100R

32 Steering

Connection Nm Nm

Handlebar to fork bridge 21 21 Twistgrip to handlebar 7 7 Handlebar weight to fixed handlebar 20 20

33 Rear wheel drive

Oil drain plug 23 23 Oil filler plug 23 23 Threaded ring 118 (Hylomar SQ 32 M) 118 (Hylomar SQ 32 M) Hexagon nut, input bevel gear 200 200

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

Locknut on free bearing journal 105 105

Strut at rear wheel drive / gearbox 43 43

Spring strut to rear frame / rear swinging arm 50

Hydraulic spring adjuster at footrest plat 22 –

clean thread + Loctite 2701

(load motorcycle with approx. 85 kg and tighten

loose strut)

10.9 screw

00.17

Model R 850/1100 GS R850/1100R

34 Brakes

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

Brake disc to rear wheel drive 21 21

Brake disc to rear wheel 21 21

Brake hose to brake caliper, front/rear 15 15 Brake hose to fitting 15 15 Brake hose to flow distributor 15 15 Flow distributor to frame 9 9

–

24 clean thread + Loctite 243

clean thread + Loctite 273

clean thread + Loctite 243

21 24

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 nec-

essary) ABS sensor 4 (handtight) 4 (handtight) ABS unit to holder M6 screw 9 9 M6 screw (Torx) 5 5 Brake line to ABS unit 15 15 Bleed screw to ABS unit 9 9

00.18

Model R 850/1100 GS R850/1100R

36 Wheels and tyres

Connection Nm Nm

Clamping screws, quick-release axle 22 22 Screw connection, quick-release axle 30 30 Screw on wheel nuts handtight, then tighten

crosswise:

Initial tightening

Final tightening

46 Frame

Rear frame to gearbox/engine 47 47

1. Screw connection on right of gearbox

2. at right of engine

3. at left of engine

4. at left of gearbox Footrest plate to gearbox 22 22 Frame to engine 82 82 Struts to frame 47

Struts to engine 58 58

105

8.8 screw 58

10.9 screw

105

8.8 screw 58

10.9 screw

Guard hoop to cylinder head 20 20 Side stand to pivot mount 42 42

clean thread + Loctite 2701

Center stand to carrier plate 21 21

clean thread + Loctite 2701

Carrier plate for center stand to engine block

M12 screw 72 72

clean thread + Loctite 2701

M 8 screw (countersunk) 21 21

clean thread + Loctite 2701

Footrest plate to rear frame

M 8 screw 21 21

Fairing support bracket to frame 20 –

00.19

Model R 850/1100 GS R850/1100R

51 Equipment

Connection Nm Nm

Ignition/steering lock to fork bridge 15 15

61 General electrical system

Horn to horn bracket 8 8 Ground (earth) strap to engine block 10 10 Rubber bushing for battery holder at gearbox 4 4

00.20

Operating materials

Item Use Order number Quantity Lubricant

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, 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

Sealants

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

Adhesives and retaining agents

Loctite 648 Structural adhesive, ultra-high speed 07 58 9 067 732 5 g bottle Loctite 638 Joint connector 07 58 9 056 030 10 ml bottle Loctite 243 Thread retainer, medium-strength 07 58 9 056 031 10 ml bottle Loctite 270 Thread retainer, strong 81 22 9 400 086 10 ml bottle Loctite 2701 Thread retainer 33 17 2 331 095 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

Cleaner

Brake cleaner Brake cleaner 81 22 9 407 704 600 ml aerosol

Testing agent

Penetrant MR 68 Crack testing agent for alu-

minum housings

Entwickler MR 70 Developer for aluminum housing

crack testing agent

81 22 9 407 494 500 ml spray

81 22 9 407 495 500 ml spray

00.21

Key to maintenance intervals

– Inspection at 1000 km (600 miles) I – BMW Service II – BMW Inspection III – Annual Service IV

Change engine oil, renew oil filter element

(Inspection I, II, III, IV)

Max

Min

RS000180

Remove screw plug.

•

Unscrew oil drain plug and drain off oil.

•

Fit new seal and screw in drain plug.

•

11 4 650

RS110950

Using oil filter wrench, BMW No. 11 4 650,

•

unscrew and remove the oil filter element. Coat sealing ring on new oil filter element with oil

•

and screw in. Top up oil/seal off.

•

Do not check oil level until at least 10 minutes af-

•

ter test run/test ride.

e Caution:

Never add engine oil above the MAX mark.

X Tightening torque:

Oil filter......................................................... 11 Nm

Oil drain plug................................................ 32 Nm

Fill quantity for engine:

- with oil filter change.............3.75 l (6.6 Imp. pints)

- without oil filter change ........3.50 l (6.2 Imp. pints)

Oil volume between

MIN and MAX marks ............0.50 l (0.88 Imp. pints)

00.22

Engine oil grade:

Brand-name HD oil for four-stroke spark-ignition engine, API classifications SE,SF,SG; combination with CC or CD specification.

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