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R 1100 RS
BMW R 1100 RS User Manual
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11.59
Dismantling/reassembling v
alve gear
holder
•
Remove bearing cap.
•
Insert a suitable drift into the bore (arrow) of the
rocker shaft, and pull the shaft out of the mount
by twistin
g it in both direc
tions.
•
Remo
ve pushro
ds.
e
Caution:
Do not accid
entally confuse r
ocker shafts and
pushro
ds.
M8 x 40
M8 x
30
M8 x 40
RS110080
108
110
Table of Contents
Table of Contents
10
Default Chapter
8
Service Data
8
Maintenance and General Instructions
9
Tightening Torques R 1100 Rs / R 1100 Rt
11
Tightening Torques R 850/1100 Gs und R 850/1100 R
20
Operating Materials
29
Change Engine Oil, Renew Oil Filter Element
30
Key to Maintenance Intervals
30
Changing Oil in Rear Wheel Drive
31
Changing Oil in Gearbox
31
Change the Oil in the Gearbox and Rear Wheel Drive
31
Battery Posts
32
Checking Battery Acid Level/Topping up if Necessary, Cleaning/Greasing
32
Renewing Air Cleaner
32
Renewing Fuel Filter
33
Checking/Renewing Spark Plugs
37
Taking up Slack at Cylinder Heads
37
Checking/Adjusting Valve Operating Clearances
38
Adjusting Poly-V Belt
39
Renewing Poly-V Belt
39
Checking Brake Pads and Discs for Wear/Renewing
40
Checking Brake Pads for Wear
40
Renewing Brake Pads – Front Brake
40
Rs] Renewing Brake Pads - Rear Brake
41
Gs/R/Rt] Renewing Brake Pads - Rear Brake
41
Checking Brake Discs for Wear
41
Checking Brake Fluid Level/Topping up
41
Bleeding/Renewing the Brake Fluid Using the Handbrake Lever/
42
Bleeding Front Brake Circuit/Renewing Fluid
42
Bleeding Rear Brake Circuit/Renewing Brake Fluid
42
Grease the Centre Stand [Rs], Side Stand and Clutch Cable Nipple
43
Rs] Cleaning and Greasing the Windshield Adjusting Shaft
43
Version with Plain Bearing Only
43
Checking Front Wheel Bearings/
45
Checking Swinging Arm Bearings, Adjusting if Necessary
45
Checking Tightness of Rear Wheel Studs
45
Rs] Check Tightness of Screws at Adjustable Handlebar
45
R] Check Steering Damper
45
Taking up Slack on Hose Clips at Intake Stub Pipen
45
Checking Throttle Synchronisation/Co Emission Value
46
Final Inspection with Road Safety and Functional Check
50
Motor
51
Table of Contents
52
Default Chapter
91
Removing Engine
91
Removing Cylinder Head Cover
105
Removing Valve Gear Holder
108
Dismantling/Reassembling Valve Gear Holder
109
Removing Cylinder Head
111
Dismantling, Checking, Repairing and Re-Assembling Cylinder Head
112
Removing Cylinder Barrel
116
Removing/Dismantling Piston
116
Assemble Pistons
117
Checking Pistons and Cylinders
117
Removing/Installing Conrod
118
Removing Alternator Mount Cover
119
Removing and Installing Alternator Cover with Engine Installed
119
Renewing Radial Shaft Seal for Rotary Breather
120
Renewing Radial Shaft Seal in Alternator Mount Cover
120
Removing Auxiliary-Shaft Drive
121
Oil Temperature Regulator
122
Removing Oil Pump
122
Dismantling Crankcase
124
Checking Conrods
127
Removing and Installing Oil Pick-Up Basket
127
Removing Conrods
127
Replacing Oil Level Sight Glass
127
Measuring Main and Big End Bearing Play
128
Install Main Bearings
129
Measuring Big End Bearing Play
130
Assembling Engine
131
Installing Conrod
131
Installing Crankshaft
132
Installing Auxiliary Shaft/Timing Chains
132
Installing Timing Chain Tensioning and Slide Rails
132
Assembling Engine Block
133
Installing Radial Seal on Crankshaft
135
Installing Clutch Housing
136
Installing Oil Pump
137
Installing Auxiliary Shaft Drive
138
Installing Pistons
139
Installing Cylinders
140
Installing Cylinder Head
141
Adjusting Valve Clearances
142
Installing Right Cylinder Head
143
Installing Left Cylinder Head
144
Installing Alternator Mount Cover
146
Installing Magnetic Gate/Belt Pulley
146
Installing Alternator
148
Installing Engin
149
Engine Electrics
150
Removing and Installing Coil and Ignition Lead
156
Checking Ignition Coil Resistance
156
Removing and Installing Alternator
157
Checking Alternator
160
Removing and Installing Starter Motor
161
Dismantling/Reassembling Starter Motor
162
Checking Starter Motor
162
Checking Starter Relay
162
Renewing Carbon Brushes
162
Removing and Installing Magnetic Gate
163
Timing the Ignition
164
Fuel Preparation and Control
165
Removing and Installing Air Cleaner
171
Removing and Installing Throttle Stub Pipe
172
Removing and Installing Injectors
173
Removing and Installing Motronic Control Unit
173
Fuel Tank and Lines
174
Removing and Installing Fuel Tank
180
Removing and Installing Fuel Filter, Fuel Pump and Fuel Level Sensor
182
Removing and Installing Fuel Filter
183
Removing and Installing Fuel Pump and Fuel Level Sensor
183
Checking Fuel Pump Pressure
184
Exhaust System
185
Clutch
189
Gearbox
191
Removing Clutch
197
Installing Clutch
197
23 Gearbox
199
Gearbox - Sectioned Drawing
205
Removing and Installing Clutch Bear-Ing/Thrust Rod/Release Lever
207
Removing and Installing Gear Shift Pedal
208
Removing Gearbox
208
Replacing Shaft Seal on Neutral Switch
210
Removing Gearbox Cover
211
Removing Selector Drum
212
Removing and Installing Input Shaft Sealing Ring at Housing End
213
Removing Gearbox Shafts
213
Removing/Dismantling/Reassembling Selector Shaft
214
Removing and Installing Selector Shaft Seal
215
Removing Deep-Groove Ball Bearing from Selector Drum
216
Installing Deep-Groove Ball Bearing on Selector Drum
217
Idler Shaft
218
Removing and Installing Deep-Groove Ball Bearing and Race/Roller Bearing for
218
Dismantling/Reassembling Input Shaft
219
Dismantling/Reassembling Output Shaft
223
Removing Deep-Groove Ball Bearing
223
Removing Spur Gears
224
Installing Spur Gears
225
Installing Gearbox Shafts
227
Removing and Installing Output Shaft Seal
228
Installing Selector Shaft
229
Installing Selector Drum
230
Installing Selector Forks
230
Shimming Gearbox Shafts
231
Measuring Shaft Bearing Play
231
Measuring Gearbox Cover
232
Example
233
Shimming the Gearbox Shafts (Without Clean Bearing)
233
Checking Friction Coefficient of Input Shaft Taper Roller Bearing
234
Removing and Installing Taper Roller Bearing Race
234
Installing Gearbox Cover
235
Removing and Installing Input Shaft Seal at Housing Cover End
236
Completing Assembly of Gearbox
237
Shimming the Gearbox Shafts (with Clean Bearing)
233
Installing Gearbox
238
31 Front Fork
239
Default Chapter
239
Steering
239
Technical Data
241
Removing and Installing Telescopic Fork
245
Removing and Installing Telescopic Fork Without Fork Bridge
245
[GS/R/RT] Removing and Installing Fork Bridge
246
Removing and Installing Pot-Type Joints
247
Removing and Installing Ball Thrust Bearing
248
[RS] Removing and Installing Fork Bridge
246
Removing and Installing Slider Tube Bridge
249
Removing and Installing Ball Joint
249
[GS/R/RT] Checking Ball Joint/Ball Thrust Bearing Friction
249
Assembly Specification for Telescopic Fork
250
[RS] Checking Ball Joint Friction
249
Dismantling Telescopic Fork
251
Dismantling/Reassembling Telescopic Fork
251
Assembling Telescopic Fork
252
Measuring Telescopic Fork
252
Check Slider Tube Bridge
252
Checking Runout of Fixed Tube
252
Dismantling/Reassembling Leading Link
253
Removing and Installing Leading Link
253
Checking the Steering Damper
254
Removing and Installing Ball Head
254
[R] Removing and Installing Steering Damper
254
Removing and Installing Front Suspension Strut
254
32 Steering
255
Technical Data
257
Removing and Installing Left Handlebar Fitting
261
With Heated Handlebar Grips
261
Without Heated Handlebar Grips
261
Removing and Installing Right Handlebar Fitting
262
With Heated Handlebar Grips
262
Without Heated Handlebar Grips
262
[RS] Removing and Installing Handlebar
263
[GS/R/RT] Removing and Installing Handlebar
264
Removing and Installing Wire Cable Distributor Block
265
Removing and Installing Throttle Cable
266
With Wire Cable Distribution Block
267
Removing and Installing Cold-Start Cable
268
With Wire Cable Distribution Block
268
Removing and Installing Clutch Cable
269
33 Rear Wheel Drive
270
Technical Data
272
Rear Wheel Drive-Sectioned Drawing
276
Removing Input Bevel Pinion
278
Removing Rear Wheel Drive
278
Removing, Dismantling, Reassembling and Installing Rear Wheel Drive
278
Disassembling Input Bevel Pinion
280
Removing Needle Roller Bearing for Input Bevel Pinion
281
Installing Needle Roller Bearing for Input Bevel Pinion
281
Assembling Input Bevel Pinion
282
Installing Input Bevel Pinion
283
Removing and Installing Taper Roller Bearing in Rear Wheel Drive
284
Removing Crown Wheel
285
Installing Crown Wheel
286
Checking/Adjusting Backlash
287
Checking Tooth Contact Pattern
288
Installing Housing Cover
289
Installing Splined Element
289
Shimming Housing Cover
289
Installing Rear Wheel Drive
290
Removing and Installing Taper Roller Bearing
292
Removing Rear Swinging Arm
292
Removing, Dismantling, Reassembling and Installing Rear Swinging Arm
292
Installing Drive Shaft
293
Removing and Installing Flexible Gaiter
293
Removing Drive Shaft
293
Checking Universal Joint for Wear
293
Installing Rear Swinging Arm
294
Removing and Installing Suspension Strut
295
34 Brakes
296
Technical Data
298
Removing and Installing Front Brake Caliper
302
Assembling Front Brake Caliper
303
Dismantling and Assembling Front Brake Caliper
303
Dismantling Front Brake Caliper
303
Removing and Installing Rear Brake Caliper
304
Dismantling Rear Brake Caliper
305
[RS] Dismantling and Assembling Rear Brake Caliper
305
Assembling Rear Brake Caliper
307
Dismantling Rear Brake Caliper
307
[GS/R/RT] Dismantling and Re-Assembling Rear Brake Caliper
307
Removing and Installing Front Brake Disc
308
[GS/R] Removing and Installing Rear Brake Disc (Attached to Rear Wheel Hub)
309
[RS] Removing and Installing Rear Brake Disc (Attached to Rear Wheel Drive)
309
[RT/R] Removing and Installing Rear Brake Disc (Attached to Rear Wheel Drive)
310
[RS] Removing and Installing Front ABS Sensor
311
[GS/R] Removing and Installing Front ABS Sensor
312
[RT] Removing and Installing Front ABS Sensor
313
Checking and Adjusting Sensor Gap
314
Marking Sensor Wheel
314
[ABS] Adjusting Front Sensor Gap
314
[RS] Removing and Installing Rear ABS Sensor
315
[GS/R/RT] Removing and Installing Rear ABS Sensor
316
Checking and Adjusting Sensor Gap
317
Marking Sensor Wheel
317
[RS] Adjusting Rear ABS Sensor Gap
317
Checking and Adjusting Sensor Gap
318
Marking Sensor Wheel
318
[GS/R/RT] Adjusting Rear ABS Sensor Gap
318
Adjusting Specification for Handbrake Lever
319
Removing, Installing, Dismantling and Assembling Front Brake Master Cylinder
319
Checking and Adjusting Relief Clear-Ance of Piston Rod
320
Removing and Installing Rear Brake Master Cylinder
320
Removing and Installing Brake Pedal
321
Removing and Installing ABS Unit
322
Installing the ABS Unit
323
Removing the ABS Unit
323
Installing the ABS Relay
324
Removing ABS Relay
324
Removing and Installing ABS Relay and Relay Base
324
Installing the ABS Relay Base
325
Removing ABS Relay Base
325
Removing and Installing Brake Line (with ABS)
327
Removing and Installing Front ABS Brake Line
327
Removing and Installing Rear ABS Brake Line
328
36 Wheels and Tyres
330
Removing and Installing Front Wheel
336
Installing Front Wheel
336
Removing Front Wheel
336
Removing and Installing Wheel Bearings
337
Installing Rear Wheel
339
Removing Rear Wheel
339
[RS/R/RT] Removing and Installing Rear Wheel (Cast Alloy)
339
Installing Rear Wheel
340
Removing Rear Wheel
340
[GS/R] Removing and Installing Rear Wheel (Spoked)
340
Static Balancing of Front Wheel/Rear Wheel
341
Checking Front/Rear Wheel Rim for Runout
342
Centering Horizontal Runout
343
[GS/R (Spoked Wheel)] Removing and Installing Spokes
343
[GS/R (Spoked Wheel)] Centering Wheel Rim
343
46 Frame
344
General View, Frame
350
[RT] General View of Fairing Sections
351
[RT] Removing and Installing Front Mudguard
352
[RT] Removing and Installing Fairing Sections
353
[RT] Removing and Installing Wind-Shield
354
[RT] Removing and Installing Inner Fairing Panel
355
[RT] Removing and Installing Upper Section of Fairing
356
[RT] Removing and Installing Fairing Holder
357
[RT] Removing and Installing Luggage Rack/Case Holder
358
[RT] Removing and Installing Rear Fairing
359
[RT] Removing and Installing Number Plate Mount
360
[RT] Removing and Installing Lower Rear Section
361
Clean Thread + Loctite
362
[RT/GS/R] Removing and Installing Center Stand
362
Removing and Installing Side Stand
363
[RT] Removing and Installing Left Footrest Plate
364
[RT] Removing and Installing Right Footrest Plate
365
[RT] Removing and Installing Frame
366
[RS] Removing and Installing Front Mudguard
367
[RS] Removing and Installing Side Sections of Fairing
368
[RS] Removing and Installing Side Sections of Full Fairing
369
[RS] Removing and Installing Wind-Shield
370
[RS] Removing and Installing Adjustable Windshield
371
[RS] Removing and Installing Inner Fairing Panel
372
[RS] Removing and Installing Top Section of Fairing
373
[RS] Removing and Installing Fairing Holder
374
Removing and Installing Frame
375
[RS] Removing and Installing Grab Handle/Case Holder
376
[RS] Removing and Installing Rear Fairing
377
[RS] Removing and Installing Number Plate Bracket
378
[RS] Removing and Installing Lower Rear Section
379
Removing and Installing Rear Section of Frame
380
[RS] Removing and Installing Center Stand
381
[RS] Removing and Installing Rear Footrest Plate
383
Master Cylinder to Footrest Plate 9
384
[RS/R] Removing and Installing Front Footrest Plate
384
[GS/R] Removing and Installing Front Mudguard
385
[GS] Removing and Installing Windshield
386
[GS] Removing and Installing Front Fairing
387
[GS] Removing and Installing Fairing Holder
388
[GS] Removing and Installing Luggage Rack
389
[GS/R] Removing and Installing Number Plate Bracket
390
[GS/R] Removing and Installing Rear Mudguard
391
[GS/R] Removing and Installing Rear Footrest Plate
392
[GS] Removing and Installing Front Footrest Plate
393
[R] Removing and Installing Rear Fairing
394
Checking Running Gear
395
Measuring Wheel Track Offset
395
51 Equipment
397
Removing and Installing Ignition Switch/Steering Lock
399
Removing and Installing Ignition/Light Switch
399
Removing and Installing Lock Barrel
399
Drilling out Lock Barrel
399
Removing and Installing Lock Barrel for Fuel Tank Filler Cap
400
Drilling out Lock Barrel
400
Removing and Installing Lock Barrel
401
[GS] Removing and Installing Dualseat Lock
401
[RS/RT] Removing and Installing Dualseat Lock
401
Removing and Installing Lock Barrel
402
[GS] Removing and Installing Helmet Lock
402
[RT] Removing and Installing Storage Compartment Lock
402
[R] Removing and Installing Dualseat Lock
402
61 General Electrical Equipment
408
Removing and Installing Central Electrical Equipment Box
414
Dismantling/Assembling Central Electrical Equipment Box
414
Relay Positions (Central Electrical Equipment Box)
415
Connections to Fuses: [RS/GS/R]
415
Connections to Fuses: [RT]
415
Frame Wiring Harness [ABS]
416
Installing Wiring Harness/Connections in Central Electrical Equipment Box
417
Installing Wiring Harness in Central Electrical Equipment Box/Output
418
[RT] Wiring Harness View from Left
419
[RT] Wiring Harness View from Right
423
[RT] Wiring Harness at Fairing Holder
426
[RT] Wiring Harness at Instrument Cluster
427
[RS] Wiring Harness View from Left
428
[RS] Wiring Harness View from Right
432
[RS] Wiring Harness at Left Switch Unit
435
[RS] Wiring Harness at Right Switch Unit
436
[GS] Wiring Harness View from Left
437
[GS] Wiring Harness View from Right
441
Removing and Installing Battery Holder
444
Technical Data
447
[RT] Removing and Installing Instrument Cluster
451
[RT] Dismantling and Assembling Instrument Cluster
451
[RS] Removing and Installing Instrument Cluster
452
[RS] Dismantling and Assembling Instrument Cluster
452
Gs] Removing and Installing Instrument Cluster
453
Gs] Dismantling and Assembling Instrument Cluster
453
R] Removing and Installing Instrument Cluster
454
Technica Data
457
[RT] Removing and Installing Headlight
461
Adjusting Headlight
461
[RS] Removing and Installing Headlight
462
Adjusting Headlight
462
[GS] Removing and Installing Headlight
463
Adjusting Headlight
464
[GS] Removing and Installing Front Flashing Turn Indicator
464
[R] Removing and Installing Headlight
464
4
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BMW R 1100 RS Specifications
General
Brand
BMW
Model
R 1100 RS
Category
Motorcycle
Language
English
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