R 1100 RT
R 1100 RS
R 850/1100 GS
R 850/1100 R
BMW Motorcycle
After Sales
Published by: |
© BMW Motorcycle |
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After Sales |
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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
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
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●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
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
R1100RT/R1100RS/R850GS/R1100GS/R850R/R1100R
Customer |
Registration No. |
Order No. |
Signature of mechanic |
BMW Inspection 1000 km/600 mls |
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BMW Service 10 000 km/6000 mls |
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BMW Inspection 20 000 km/12 000 mls |
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BMW Annual Service |
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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
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 |
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R 1100 RT/R 1100 RS/R 1100 GS/R 1100 R/R 850 R |
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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 |
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Measuring unit or |
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specification |
3.75 |
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litre |
5.50 |
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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
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 |
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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 |
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(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
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/ |
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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 |
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(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/ |
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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 |
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R 1100 RS |
R 1100 RT |
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11 Engine |
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Connection |
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Nm |
Nm |
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Cylinder head |
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Tightening sequence: |
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1. |
Tighten cylinder head nuts (oiled) crosswise |
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20 |
20 |
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1.1 Tighten all nuts to correct torque for joint |
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1.2 Tighten all nuts to correct angle |
90° |
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1.3 Tighten all nuts to correct angle |
90° |
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2. M 10 screw |
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40 |
40 |
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3. M 6 screw |
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9 |
9 |
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After 1000 km, tighten cylinder head nuts crosswise: |
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1. |
Unfasten one nut |
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2. |
Tighten one nut to initial value |
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20 |
20 |
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3. |
Tighten nut to wrench angle |
180° |
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4. |
Unfasten/retighten M10 screw |
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40 |
40 |
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Bearing cap on rocker shaft |
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15 |
15 |
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Locknut on valve clearance adjusting screw |
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8 |
8 |
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Cylinder head cover to cylinder head |
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8 |
8 |
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Camshaft end cover to cylinder head |
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9 |
9 |
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Air intake connection to cylinder head |
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9 |
9 |
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Camshaft |
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Chain sprocket to camshaft |
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65 |
65 |
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Camshaft bearing cap |
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15 |
15 |
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Rotary breather |
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Vent line to alternator mount cover |
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M 8 screw |
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20 |
20 |
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Banjo screw |
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25 |
25 |
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Alternator mount cover |
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M 6 screw |
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9 |
9 |
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M 8 screw |
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20 |
20 |
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Auxiliary shaft |
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Chain sprocket to crankshaft |
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10 |
10 |
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Chainwheel to auxiliary shaft |
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70 |
70 |
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Chain tensioner housing to engine block |
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9 |
9 |
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00.3
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Model |
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R 1100 RS |
R 1100 RT |
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11 Engine |
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Connection |
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Nm |
Nm |
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Oil filter |
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Oil filter |
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11 |
11 |
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Oil drain plug |
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32 |
32 |
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Oil pump |
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Mesh filter basket to engine block |
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9 |
9 |
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Oil pump cover |
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9 |
9 |
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Pressure relief valve |
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35 |
35 |
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Oil pressure switch |
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30 |
30 |
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Oil cooler |
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Oil cooler pipe to engine block |
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10 |
10 |
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Cooling oil line - banjo screw |
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25 |
25 |
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Cooling oil line - banjo screw with oil vent valve |
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25 |
25 |
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Oil lines to oil cooler |
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25 |
– |
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Oil cooler to holder |
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9 |
9 |
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Oil cooler return line to engine block |
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35 |
35 |
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Oil cooler feed line to frame |
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20 |
20 |
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Oil cooler feed line to engine block |
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25 |
25 |
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Screw-in union for oil cooler connection at |
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35 |
35 |
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engine block |
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Clean threads and apply Loctite 603 to inner and |
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outer threads and in the contact face area |
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Oil cooler hose at oil thermostat |
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– |
40 |
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Cylinders |
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Tightening sequence |
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M 8 screw |
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20 |
20 |
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M 6 screw |
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9 |
9 |
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Chain guide rail pivot screw |
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18 |
18 |
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Timing chain |
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Chain tensioner |
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32 |
32 |
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Connecting rod |
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Big end cap |
Joint torque |
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20 |
20 |
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Additional wrench angle |
80° |
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Crankcase |
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Tightening sequence: |
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M 10 screw (oiled) |
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45 |
45 |
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M 8 screw (oiled) |
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20 |
20 |
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M 6 screw |
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9 |
9 |
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00.4
Model |
R 1100 RS |
R 1100 RT |
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12 Engine electrical system |
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Connection |
Nm |
Nm |
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Starter motor to engine |
20 |
20 |
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Starter cover to gearbox housing |
7 |
– |
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Positive lead to starter motor |
10 |
10 |
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Alternator to alternator support cover |
20 |
20 |
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Tensioning and retaining strap at alternator |
20 |
20 |
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Spacer at alternator |
20 |
20 |
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Positive lead to alternator |
15 |
15 |
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Belt pulley at alternator |
50 |
50 |
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Belt pulley to crankshaft |
50 |
50 |
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Poly-V belt preload |
8 |
8 |
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Spark plug |
20 |
20 |
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13 Fuel preparation and control |
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Temperature sensor on engine block |
25 |
25 |
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16 Fuel tank and lines |
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Fuel tank to rear frame |
22 |
22 |
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Fuel pump assembly to tank |
6 |
6 |
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18 Exhaust system |
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Muffler to footrest |
35 |
35 |
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Manifold to cylinder head (with strap) |
22 |
22 |
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(with jacket pipe) |
18 |
18 |
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Muffler to support plate for center stand |
20 |
20 |
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Clip on muffler |
50 |
50 |
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Grease clamping face with Never Seez |
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Oxygen sensor (lambda probe) to muffler |
55 |
55 |
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Grease with Never Seez |
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00.5
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Model |
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R 1100 RS |
R 1100 RT |
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21 Clutch |
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Connection |
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Nm |
Nm |
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Clutch housing |
Joint torque |
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40 |
40 |
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oil screw threads lightly |
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Additional wrench angle |
32° |
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Housing cover |
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18 |
18 |
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Locknut on release lever |
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22 |
22 |
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23 Gearbox |
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Oil filler plug |
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23 |
23 |
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Oil drain plug |
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23 |
23 |
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Gearbox cover to gearbox housing |
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9 |
9 |
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Screw for neutral detent |
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13 |
13 |
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clean thread + Loctite 243 |
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Oil guide plate at gearbox housing |
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9 |
9 |
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clean thread + Loctite 573, also apply Loctite 573 |
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to sealing face between oil baffle plate and gear- |
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box housing |
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Gearbox to engine block |
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22 |
22 |
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Clutch lever to gearbox housing |
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18 |
18 |
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Selector lever to selector shaft |
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9 |
9 |
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Pedal to footrest plate |
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35 |
18 |
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00.6
Model |
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R 1100 RS |
R 1100 RT |
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31 Front fork |
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Connection |
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Nm |
Nm |
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Clamp between fixed tubes and fork bridge |
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22 |
– |
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Screw connection between fixed tube and |
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– |
45 (free from oil and |
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fork bridge |
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grease) |
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Control arm to ball joint |
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130 |
130 |
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clean thread + Loctite 2701 |
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Fork bridge to ball joint |
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130 |
– |
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clean threads |
– |
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+ Loctite 2701 |
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Threaded journal to frame |
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– |
130 |
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– |
clean threads |
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+ Loctite 243 |
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Ball joint to |
fork slider tube bridge |
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230 |
230 |
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Frame |
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230 |
– |
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Slider tube bridge to slider tube |
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22 |
– |
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clean thread |
– |
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+ Loctite 243 |
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Screw plug to fixed fork tube |
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18 |
pressed fit, |
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do not release |
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Clamping screws, quick-release axle |
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22 |
22 |
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Control arm to engine |
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right |
73 |
73 |
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Screw cap |
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left |
42 |
42 |
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apply light coat of Never Seez to thread |
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Spring strut to frame |
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47 |
47 |
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Spring strut to control arm |
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43 |
43 |
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8.8 screw |
8.8 screw |
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50 |
50 |
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10.9 screw |
10.9 screw |
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32 Steering |
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Handlebar at rubber mount |
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40 |
– |
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Rubber mount at fork bridge |
|
40 |
– |
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Handlebar to fork bridge |
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– |
21 |
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Twistgrip to handlebar |
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7 |
7 |
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Handlebar weight to fixed handlebar |
|
20 |
– |
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Handlebar weight to handlebar |
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– |
20 |
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Handlebar weight to adjustable handlebar |
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7 |
7 |
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clean threads |
– |
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+ Loctite 2701 |
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00.7
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Model |
R 1100 RS |
R 1100 RT |
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33 Rear wheel drive |
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Connection |
Nm |
Nm |
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Oil drain plug |
23 |
23 |
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||||
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Oil filler plug |
23 |
23 |
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Threaded ring |
118 (Hylomar SQ 32 M) |
118 (Hylomar SQ 32 M) |
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Hexagon nut, input bevel gear |
200 |
200 |
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clean thread + Loctite 273 |
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Housing cover |
35 |
35 |
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Fixed bearing journal |
150 |
150 |
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Swinging arm to gearbox/ |
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Swinging arm at rear wheel drive |
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clean thread + Loctite 2701 |
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Free bearing journal |
7 |
7 |
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Swinging arm to gearbox/ |
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Swinging arm at rear wheel drive |
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clean thread + Loctite 2701 |
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Locknut on free bearing journal |
105 |
105 |
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clean thread + Loctite 2701 |
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Strut at rear wheel drive / gearbox |
43 |
43 |
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load motorcycle with approx. 85 kg and tighten |
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loose strut |
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Spring strut to rear frame / rear swinging |
43 |
43 |
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arm |
8.8 screw |
8.8 screw |
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50 |
50 |
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10.9 screw |
10.9 screw |
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Hydraulic spring adjuster at footrest plate |
– |
22 |
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00.8
Model |
R 1100 RS |
R 1100 RT |
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34 Brakes |
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Connection |
Nm |
Nm |
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Brake caliper to slider tube |
40 |
40 |
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Brake caliper to rear wheel drive |
40 |
40 |
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Brake disc to front wheel |
21 |
21 |
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Brake disc to rear wheel drive |
21 |
21 |
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clean thread + Loctite 273 |
|
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Brake hose to brake caliper, front/rear |
15 |
15 |
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Brake hose to fitting |
15 |
15 |
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Brake hose to flow distributor |
15 |
15 |
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Flow distributor to frame |
9 |
9 |
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Flow distributor to slider tube bridge |
9 |
9 |
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Flow distributor to holder/slider tube |
– |
9 |
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Bleed screw on front brake caliper |
7 |
7 |
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Bleed screw on rear brake caliper |
7 |
4 |
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Master cylinder to footrest plate |
9 |
9 |
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Brake pedal to footrest plate |
37 |
37 |
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Handbrake lever pivot pinl |
8 |
8 |
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the Tuflok blue thread retaining agent can be |
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slackened off and tightened several times if nec- |
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essary |
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ABS sensor |
4 (handtight) |
4 (handtight) |
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ABS unit to holder |
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M6 screw |
9 |
9 |
|
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M6 screw (Torx) |
5 |
5 |
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|
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Brake line to ABS unit |
15 |
15 |
|
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Bleed screw to ABS unit |
9 |
9 |
|
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36 Wheels and tyres |
|
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|
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Clamping screws, quick-release axle |
22 |
22 |
|
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Screw connection, quick-release axle |
30 |
30 |
|
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|
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Screw on wheel nuts handtight, then tighten |
|
|
|
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crosswise: |
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Initial tightening |
50 |
50 |
|
|
Final tightening |
105 |
105 |
|
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||
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00.9
|
|
Model |
R 1100 RS |
R 1100 RT |
|
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46 Frame |
|
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Connection |
Nm |
Nm |
|
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|
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Rear frame to gearbox/engine |
47 |
47 |
|
||||
|
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Screw connection on right of gearbo |
|
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|
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at right of engine |
|
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at left of engine |
|
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||
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at left of gearbox |
|
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Footrest plate to gearbox |
22 |
22 |
|
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Frame to engine |
82 |
82 |
|
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Struts to frame |
47 |
47 |
|
|
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8.8 screw |
8.8 screw |
|
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58 |
58 |
|
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10.9 screw |
10.9 screw |
|
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Struts to engine |
47 |
47 |
|
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|
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Guard hoop to cylinder head |
20 |
20 |
|
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|
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Side stand to pivot mount |
42 |
42 |
|
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clean thread + Loctite 2701 |
|
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Center stand to carrier plate |
21 |
21 |
|
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clean thread + Loctite 2701 |
|
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Carrier plate for center stand to engine block |
|
|
|
|
M12 screw |
72 |
72 |
|
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|
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clean thread + Loctite 2701 |
|
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|
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M 8 screw (countersunk) |
21 |
21 |
|
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clean thread + Loctite 2701 |
|
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|
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Grab handle to rear frame |
9 |
9 |
|
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|
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Lifting handle to rear frame |
10 |
10 |
|
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Footrest plate to rear frame |
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M 6 screw |
9 |
– |
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|
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M 8 screw |
21 |
21 |
|
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|
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M 10 screw |
42 |
– |
|
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|
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Footrest to footrest plate |
42 |
– |
|
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|
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Fairing support bracket to frame |
20 |
20 |
|
|
|
|
|
00.10
Model |
R 1100 RS |
R 1100 RT |
|
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51 Equipment |
|
|
|
|
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|
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Connection |
Nm |
Nm |
|
|
|
|
|
|
|
Ignition/steering lock to fork bridg |
15 |
15 |
|
|
|
||||
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61 General electrical system |
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|
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Horn to horn bracket |
8 |
20 |
|
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|
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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 |
|
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|
11 Engine |
|
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|
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Connection |
|
Nm |
Nm |
|
|
||||||
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|
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Cylinder head |
|
|
|
|
|
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|
|
|
|
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 |
|
|
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Auxiliary shaft |
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Chain sprocket to crankshaft |
|
10 |
10 |
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Chainwheel to auxiliary shaft |
|
70 |
70 |
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Chain tensioner housing to engine block |
|
9 |
9 |
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00.12
Model |
|
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R 850/1100 GS |
R 850/1100 R |
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11 Engine |
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Connection |
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Nm |
Nm |
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Oil filter |
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Oil filter |
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11 |
11 |
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Oil drain plug |
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32 |
32 |
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Oil pump |
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Mesh filter basket to engine block |
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9 |
9 |
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Oil pump cover |
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9 |
9 |
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Pressure relief valve |
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35 |
35 |
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Oil pressure switch |
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30 |
30 |
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Oil cooler |
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Oil cooler pipe to engine block |
|
10 |
10 |
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Cooling oil line - banjo screw |
|
25 |
25 |
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Cooling oil line - banjo screw with oil vent valve |
|
25 |
25 |
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Oil lines to oil cooler |
|
25 |
– |
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Oil cooler to holder |
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9 |
9 |
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Oil cooler return line to engine block |
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35 |
35 |
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Oil cooler feed line to engine block |
|
25 |
25 |
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Screw-in union for oil cooler connection at |
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35 |
35 |
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engine block |
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Clean threads and apply Loctite 603 to inner and |
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outer threads and in the contact face area |
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Cylinders |
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Tightening sequence: |
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1. M 8 screw |
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20 |
20 |
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2. M 6 screw |
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9 |
9 |
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3. |
Chain guide rail pivot screw |
|
18 |
18 |
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Timing chain |
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Chain tensioner |
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32 |
32 |
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Connecting rod |
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Big end cap |
Joint torque |
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20 |
20 |
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Additional wrench angle |
80° |
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Crankcase |
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Tightening sequence: |
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||
1. |
M 10 screw (oiled) |
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45 |
45 |
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2. |
M 8 screw (oiled) |
|
20 |
20 |
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3. M 6 screw |
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9 |
9 |
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00.13
|
|
Model |
|
R 850/1100 GS |
R 850/1100 R |
|
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12 Engine electrical system |
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Connection |
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Nm |
Nm |
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Starter motor to engine |
|
20 |
20 |
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||||
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Starter cover to gearbox housing |
|
7 |
7 |
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Positive lead to starter motor |
|
10 |
10 |
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Alternator to alternator support cover |
20 |
20 |
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|||||
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Tensioning and retaining strap at alternator |
20 |
20 |
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Spacer at alternator |
|
20 |
20 |
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Positive lead to alternator |
|
15 |
15 |
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Belt pulley at alternator |
|
50 |
50 |
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Belt pulley to crankshaft |
|
50 |
50 |
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Poly-V belt preload |
|
8 |
8 |
|
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Spark plug |
|
20 |
20 |
|
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13 Fuel preparation and control |
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Temperature sensor on engine block |
25 |
25 |
|
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16 Fuel tank and line |
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Fuel tank to rear frame |
|
22 |
22 |
|
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Fuel pump assembly to tank |
|
6 |
6 |
|
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Strut to tank |
|
– |
15 |
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18 Exhaust system |
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Muffler to rear frame |
|
24 |
24 |
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Manifold to cylinder head |
(with strap) |
22 |
22 |
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(with jacket pipe) |
18 |
18 |
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Muffler to support plate for center stand |
20 |
20 |
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Clip on muffler |
|
50 |
50 |
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Grease clamping face with Never Seez |
|
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|
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Oxygen sensor (lambda probe) to muffler |
55 |
55 |
|
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|
|
Grease with Never Seez |
|
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|
|
00.14
Model |
|
|
R 850/1100 GS |
R 850/1100 R |
|
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|
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21 Clutch |
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Connection |
|
|
Nm |
Nm |
|
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|
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Clutch housing |
Joint torque |
|
40 |
40 |
|
|
|
||||||
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|
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oil screw threads lightly |
|
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Additional wrench angle |
32° |
|
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||
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Housing cover |
|
|
18 |
18 |
|
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|
|||||
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Locknut on release lever |
|
22 |
22 |
|
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23 Gearbox |
|
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Oil filler plug |
|
|
23 |
23 |
|
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|
|
Oil drain plug |
|
|
23 |
23 |
|
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|
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Gearbox cover to gearbox housing |
|
9 |
9 |
|
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|
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Screw for neutral detent |
|
13 |
13 |
|
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|
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clean thread + Loctite 243 |
|
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|
|
Oil guide plate at gearbox housing |
|
9 |
9 |
|
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|
|
clean thread + Loctite 573, also apply Loctite 573 |
|
|
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|
|
to sealing face between oil baffle plate and gear- |
|
|
|
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|
|
box housing |
|
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|
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Gearbox to engine block |
|
22 |
22 |
|
|
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|
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Clutch lever to gearbox housing |
|
18 |
18 |
|
|
|
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|
|
Selector lever to selector shaft |
|
9 |
9 |
|
|
|
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|
|
Pedal to footrest plate |
|
35 |
35 |
|
|
|
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|
|
00.15
|
|
Model |
|
|
R 850/1100 GS |
R 850/1100 R |
|
|
|
|
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|
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|
|
31 Front fork |
|
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|
|
Connection |
|
|
Nm |
Nm |
|
|
|
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|
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|
|
Screw connection between fixed tube and |
|
45 (free from oil and |
45 |
(free from oil and |
|
|
|
||||||
|
|
fork bridge |
|
|
grease) |
grease) |
|
|
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|
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|
|
Control arm to ball joint |
|
|
130 |
130 |
|
|
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|
|
clean thread + Loctite 2701 |
|
|
|
|
|
|
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|
||
|
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|
||
|
|
Threaded journal to frame |
|
130 |
130 |
||
|
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|
|
clean threads + Loctite 243 |
|
|
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|
|
Ball joint to |
fork slider tube bridge |
|
230 |
230 |
|
|
|
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|
|
|
|
|
Slider tube bridge to slider tube |
|
22 |
22 |
|
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|
|
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) |
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ABS unit to holder |
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M6 screw |
9 |
9 |
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M6 screw (Torx) |
5 |
5 |
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Brake line to ABS unit |
15 |
15 |
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Bleed screw to ABS unit |
9 |
9 |
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00.18
Model |
R 850/1100 GS |
R 850/1100 R |
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36 Wheels and tyres |
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Connection |
Nm |
Nm |
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Clamping screws, quick-release axle |
22 |
22 |
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Screw connection, quick-release axle |
30 |
30 |
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Screw on wheel nuts handtight, then tighten |
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crosswise: |
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Initial tightening |
50 |
50 |
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Final tightening |
105 |
105 |
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46 Frame |
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Rear frame to gearbox/engine |
47 |
47 |
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1. Screw connection on right of gearbox |
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2. at right of engine |
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3. at left of engine |
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4. at left of gearbox |
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Footrest plate to gearbox |
22 |
22 |
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Frame to engine |
82 |
82 |
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Struts to frame |
47 |
47 |
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8.8 screw |
8.8 screw |
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58 |
58 |
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10.9 screw |
10.9 screw |
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Struts to engine |
58 |
58 |
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Guard hoop to cylinder head |
20 |
20 |
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Side stand to pivot mount |
42 |
42 |
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clean thread + Loctite 2701 |
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Center stand to carrier plate |
21 |
21 |
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clean thread + Loctite 2701 |
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Carrier plate for center stand to engine block |
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M12 screw |
72 |
72 |
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clean thread + Loctite 2701 |
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M 8 screw (countersunk) |
21 |
21 |
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clean thread + Loctite 2701 |
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Footrest plate to rear frame |
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M 8 screw |
21 |
21 |
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Fairing support bracket to frame |
20 |
– |
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00.19
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Model |
R 850/1100 GS |
R 850/1100 R |
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51 Equipment |
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Connection |
Nm |
Nm |
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Ignition/steering lock to fork bridge |
15 |
15 |
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61 General electrical system |
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Horn to horn bracket |
8 |
8 |
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Ground (earth) strap to engine block |
10 |
10 |
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Rubber bushing for battery holder at gearbox |
4 |
4 |
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00.20
Item |
Use |
Order number |
Quantity |
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Lubricant |
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Optimoly MP 3 |
High-performance lubricating paste |
07 55 9 062 476 |
100 g tube |
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Optimoly TA |
High-temperature assembly paste |
18 21 9 062 599 |
100 g tube |
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Silicone grease 300, heavy |
Damping grease |
07 58 9 058 193 |
10 g tube |
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Retinax A |
(Taper) roller bearing grease |
81 22 9 407 710 |
100 g tube |
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Contact spray |
Contact spray |
81 22 9 400 208 |
300 ml aerosol |
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Sealants |
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3-Bond 1209 |
Surface sealant |
07 58 9 062 376 |
30 g tube |
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Loctite 574 |
Surface sealant |
81 22 9 407 301 |
50 ml tube |
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Curil K 2 |
Heat-conductive sealant |
81 22 9 400 243 |
250 g can |
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Hylomar SQ 32 M |
Permanently elastic sealant |
81 22 9 400 339 |
100 g tube |
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Adhesives and retaining |
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agents |
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Loctite 648 |
Structural adhesive, ultra-high speed |
07 58 9 067 732 |
5 g bottle |
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Loctite 638 |
Joint connector |
07 58 9 056 030 |
10 ml bottle |
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Loctite 243 |
Thread retainer, medium-strength |
07 58 9 056 031 |
10 ml bottle |
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Loctite 270 |
Thread retainer, strong |
81 22 9 400 086 |
10 ml bottle |
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Loctite 2701 |
Thread retainer |
33 17 2 331 095 |
10 ml bottle |
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Loctite 454 |
Cyanacrylate adhesive |
07 58 9 062 157 |
20 g tube |
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3-Bond 1110 B |
Joint adhesive |
07 58 9 056 998 |
5 g tube |
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Cleaner |
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Brake cleaner |
Brake cleaner |
81 22 9 407 704 |
600 ml aerosol |
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Testing agent |
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Penetrant MR 68 |
Crack testing agent for alu- |
81 22 9 407 494 |
500 ml spray |
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minum housings |
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Entwickler MR 70 |
Developer for aluminum housing |
81 22 9 407 495 |
500 ml spray |
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crack testing agent |
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00.21
– Inspection at 1000 km (600 miles) |
I |
|
– |
BMW Service |
II |
– |
BMW Inspection |
III |
– |
Annual Service |
IV |
(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