Bmw R850 1100GS (2000) User Manual [ru]

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

11Motor

12Engine electrics

13Fuel preparation and control

16Fuel tank and lines

18Exhaust system

21Clutch

23Gearbox

31Front fork

32Steering

33Rear wheel drive

>> Continuation

>> Continuation

Group / Chapter

34 Brakes

36 Wheels and tyres

46 Frame

51Equipment

52Seat

61 General electrical equipment

62Instruments

63Lights

<< Back

BMW AG Motorcycle Division

Maintenance Schedule

R1100RT/R1100RS/R850GS/R1100GS/R850R/R1100R

Customer

Registration No.

Order No.

Signature of mechanic

BMW Inspection 1000 km/600 mls		BMW Service 10 000 km/6000 mls		BMW Inspection 20 000 km/12 000 mls		BMW Annual Service

Change engine oil when engine is warm, renew oil filter cartridge 1)

Change oil in manual transmission and rear wheel drive when at operating temperature Retighten cylinder head nuts

Adjust valve clearance

Check spark plugs

Renew spark plugs

Renew fuel filter 3) *)

Check battery acid level, if necessary top up with distilled water

Clean and grease battery terminals

Renew intake air cleaner 2)

Check throttle cables for free movement, abrasion and kinking, renewing if necessary *)

Check clutch clearance, adjust if necessary

Adjust Poly-V-belt [b SI 12 020 95 (700)] 4) 5)

Retighten hose clips at intake pipe

Check brake pads and discs for wear, renew if necessary *)

Check front/rear brake fluid level, top up if necessary *) [b SI 00 027 95 (716)]

Check brake system with regard to function, leaks; repair/renew as required *)

Renew brake fluid at least once a year

Check wheel bearings, renew if necessary *)

Check swinging arm bearing (no play), adjust if necessary *)

Check steering damper (R850/1100R)

Lubricate side stands, centre stand (R 1100 RS) and nipple for clutch cable assembly

Check side stand switch for damage and correct operation [b SI 46 033 96 (722)]

Check fit of rear wheel bolts

Check bolts of control arm to specified torque

Clean and grease shaft for windshield adjustment (R 1100 RS)

Grease lower eye of front spring strut (R 1100 RS slide bearing)

Check idle speed, throttle synchronisation and CO value, adjust if necessary

Final inspection with safety/operating check:

–condition of tyres and wheels, rims and spokes, tyre pressures

–lights and signal systems

–telltale and warning lights

–clutch and gear shift

–handbrake and footbrake, steering

–instruments

–test ride, if necessary

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

2)in very dirty or dusty conditions, renew the intake air cleaner element every 10,000 km (6,000 miles), or even more frequently if necessary

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

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

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

*) invoiced as a separate item

Order No. 01 71 7 654 296

UX-VS-2, 03.99

Printed in Germany

BMW AG Motorcycle Division Pre-delivery check

R1100RT/R1100RS/R850GS/R1100GS/R850R/R1100R

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	B
Service Data
R 1100 RT/R 1100 RS/R 1100 GS/R 1100 R/R 850 R

Designation

Oilcapacities

Engine (incl. filter)

Engine (without filter renewal)

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

CO value (without catalytic converter)

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

Data		Measuring unit or
		specification
3.75		litre
5.50		litre

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

fresh fill	1.0
change	0.8
fresh fill	0.25
change	0.23

E 0.15 / A 0.30

disconnect at 6° b TDC

Bosch FR5DTC 0.8 1.0

1000 +150

1.5±0.5

<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

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

litre litre

litre litre

mm

mm mm

1/min

Vol %

mm play

mm play

mmplay

mm thread

mmplay

bar bar

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

Order No. 01 71 9 799 171

UX-VS-1, 7/95

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

...............................................................................................33

.................................................................33

..............................................................................33

......................................................................................32

................................................................................................32

Page

Contents

Checking brake pads for wear Renewing brake pads – front brake [RS] Renewing brake pads - rear brake

[GS/R/RT] Renewing brake pads - rear brake Checking brake discs for wear

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

00.2

00

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			35	35
		engine block
					Clean threads and apply Loctite 603 to inner and
					outer threads and in the contact face area
		Oil cooler hose at oil thermostat			–	40
		Cylinders
		Tightening sequence
		M 8 screw			20	20
		M 6 screw			9	9
		Chain guide rail pivot screw			18	18
		Timing chain
		Chain tensioner			32	32
		Connecting rod
		Big end cap	Joint torque		20	20
			Additional wrench angle	80°
		Crankcase
		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			–	45 (free from oil and
fork bridge				grease)
Control arm to ball joint			130	130
			clean thread + Loctite 2701
Fork bridge to ball joint			130	–
			clean threads	–
			+ Loctite 2701
Threaded journal to frame			–	130
			–	clean threads
				+ Loctite 243
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,
				do not release
Clamping screws, quick-release axle			22	22
Control arm to engine		right	73	73
Screw cap		left	42	42
			apply light coat of Never Seez to thread
Spring strut to frame			47	47
Spring strut to control arm			43	43
			8.8 screw	8.8 screw
			50	50
			10.9 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

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	150	150
		Swinging arm to gearbox/
		Swinging arm at rear wheel drive
			clean thread + Loctite 2701
		Free bearing journal	7	7
		Swinging arm to gearbox/
		Swinging arm at rear wheel drive
			clean thread + Loctite 2701
		Locknut on free bearing journal	105	105
			clean thread + Loctite 2701
		Strut at rear wheel drive / gearbox	43	43
			load motorcycle with approx. 85 kg and tighten
			loose strut
		Spring strut to rear frame / rear swinging	43	43
		arm	8.8 screw	8.8 screw
			50	50
			10.9 screw	10.9 screw
		Hydraulic spring adjuster at footrest plate	–	22

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	50
Final tightening	105	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	47
			8.8 screw	8.8 screw
			58	58
			10.9 screw	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
		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	R 850/1100 R
		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

00.12

Model				R 850/1100 GS	R 850/1100 R
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				35	35
engine block
				Clean threads and apply Loctite 603 to inner and
				outer threads and in the contact face area
Cylinders
Tightening sequence:
1. M 8 screw				20	20
2. M 6 screw				9	9
3.	Chain guide rail pivot screw			18	18
Timing chain
Chain tensioner				32	32
Connecting rod
Big end cap		Joint torque		20	20
		Additional wrench angle	80°
Crankcase
Tightening sequence:
1.	M 10 screw (oiled)			45	45
2.	M 8 screw (oiled)			20	20
3. M 6 screw				9	9

00.13

		Model		R 850/1100 GS	R 850/1100 R
		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	R 850/1100 R
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	R 850/1100 R
		31 Front fork
		Connection			Nm	Nm
		Screw connection between fixed tube and			45 (free from oil and	45	(free from oil and
		fork bridge			grease)	grease)
		Control arm to ball joint			130	130
					clean thread + Loctite 2701
		Threaded journal to frame			130	130
					clean threads + Loctite 243
		Ball joint to	fork slider tube bridge		230	230
		Slider tube bridge to slider tube			22	22
					clean threads
					+ Loctite 243
		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
					apply light coat of Never Seez to thread
		Spring strut to frame			47	47
		Spring strut to control arm			50	50
					10.9 screw	10.9 screw
		Steering damper to fork slider bridge mount			–	20
						clean thread
						+ Loctite 2701
		Steering damper mount to fork slider bridge			–	9
						clean thread
						+ 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	R 850/1100 R
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	150	150
Swinging arm at gearbox
Swinging arm at rear wheel drive
	clean thread + Loctite 2701
Free bearing journal	7	7
Swinging arm to gearbox/
Swinging arm to rear wheel drive
	clean thread + Loctite 2701
Locknut on free bearing journal	105	105
	clean thread + Loctite 2701
Strut at rear wheel drive / gearbox	43	43
	(load motorcycle with approx. 85 kg and tighten
	loose strut)
Spring strut to rear frame / rear swinging arm	50	50
	10.9 screw	10.9 screw
Hydraulic spring adjuster at footrest plat	22	–

00.17

		Model	R 850/1100 GS	R 850/1100 R
		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	–	21
		Spoked whee	24	24
			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, 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 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	R 850/1100 R
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	50	50
Final tightening	105	105
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	47
	8.8 screw	8.8 screw
	58	58
	10.9 screw	10.9 screw
Struts to engine	58	58
Guard hoop to cylinder head	20	20
Side stand to pivot mount	42	42
	clean thread + Loctite 2701
Center stand to carrier plate	21	21
	clean thread + Loctite 2701
Carrier plate for center stand to engine block
M12 screw	72	72
	clean thread + Loctite 2701
M 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	R 850/1100 R
		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-	81 22 9 407 494	500 ml spray
	minum housings
Entwickler MR 70	Developer for aluminum housing	81 22 9 407 495	500 ml spray
	crack testing agent

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 after test run/test ride.

eCaution:

Never add engine oil above the MAX mark.

XTightening torque:
Oil filter.........................................................		11 Nm
Oil drain plug................................................		32 Nm
Fill quantity for engine:
- with oil filter change .............	3.75 l (6.6	Imp. pints)
- without oil filter change ........	3.50 l (6.2	Imp. pints)
Oil volume between
MIN and MAX marks ............	0.50 l (0.88	Imp. pints)

Engine oil grade:

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

00.22