BMWR1100Srepairmanual

BMWAGMotorcycleDivisionAfterSalesR1100SRepairManualPublishedby:©BMWAGMotorcycleDivisionAfterSalesUX-VS-2Allrightsreserved.Nottobereprinted,translatedorduplicatedeitherwhollyorinpartwithoutpriorwrittenpermission.Errorsandomissionsexcepted;subjecttotechnicalamendment.ProducedinGermany06/99IntroductionThisrepairmanualwillhelpyoutoperformallthemainmaintenanceandrepairworkcorrectlyandefficient-ly.ItshouldbeconsultedregularlybyworkshoppersonnelasanadditiontothepracticalandtheoreticalknowledgeobtainedinTrainingSchoolcourses.ItisacontributiontowardsachievingevenhigherServicequality.AllinformationinbothtextandillustrationsreferstomotorcyclesinstandardconditionorwithgenuineBMWaccessoriesinstalled,andnottomotorcycleswhichhavebeenmodifiedinanywaytodepartfromthemanufacturer’sspecification.●Therepairmanualisstructuredinthelogicalsequenceoftheworktobeperformed:Removal,Dis-assembly,Repair,Assembly,Installation.●Theentirecontentsaredividedintoindividualchapters,correspondingtotheConstructionGroups.11.10Chap.Pagenumberwithinchapter●WorktobeperformedduringanInspectionisdescribedinGroup“00”.ThevariousinspectionroutinesarenumberedI,II,IIIandIV.Thisnumberingisrepeatedintheworkdescriptionswhichfollow,sothatworkcantakeplacewithoutinterruption.●UseoftheBMWspecialtoolsneededforcertaintasksisdescribedintheworkinstructions.Iftheneedarises,repairinstructionsarealsoissuedintheformofServiceInformation.Thisinformationisofcourseincorporatedintothenextissueoftherepairmanual.WealsorecommendyoutoconsultthedetailedillustrationsonthePartsmicrofichesasanadditionalsourceofinformation.BMWAGMotorcycleDivisionAfterSalesPublishedby:BMWAG,SparteMotorradHufelandstr.6D-80937MünchenAllrightsreserved.Nottobereprinted,translatedorduplicatedeitherwhollyorinpartwithoutpriorwrittenpermission.Errorsandomissionsexcepted;subjecttotechnicalamendment.ProducedinGermany300Maintenanceandgeneralinstructions11Engine12Engineelectrics13Fuelpreparationandcontrol16Fueltankandlines18Exhaustsystem21Clutch23Gearbox31Frontfork32Steering33RearwheeldriveContentsGroup/Chapter534Brakes36Wheelsandtyres46Frame51Equipment52Seat61Generalelectricalequipment62Instruments63LightsGroup/ChapterOrderNo.01717654263UX-VS-2,3.99PrintedinGermanyCustomerLicenceplateNo.OrderNo.Mechanic’ssignatureBMWInspectionat1,000km(600miles)BMWServiceevery10,000km(6,000miles)BMWInspectionevery20,000km(12,000miles)BMWAnnualServiceReadoutthefaultmemorywiththeBMWMoDiTeCunitChangetheoilwhileatregularoperatingtemperatureandrenewtheoilfilterelementifmotorcycleisusedonlyforshortjourneysoratoutsidetemperaturesunder0°C,every3months,butatleastevery3,000km(1,800miles)*)Changetheoilinthegearboxwhileatregularoperatingtemperatureatleastevery2yearsevery2yearsChangetheoilintherearwheeldrivewhileatregularoperatingtemperatureCleantheinductivesensorattherearwheelevery40,000km(24,000miles)oratleastevery2years*)40,000(24,000)every2yearsRenewfuelfilter*)normallyevery40,000km(24,000miles),iffuelqualityispoorevery20,000km(12,000miles)40,000(24,000)Checkbatteryacidlevel,ifnecessaryadddistilledwaterClean/greasebatterypolesifnecessaryRenewingintakeaircleanerelementinverydustyordirtyoperatingconditions,renewtheintakeaircleanerelementevery10,000km(6,000miles)orevenmoreoftenifnecessary*)RenewPoly-Vbelt*)RenewPoly-Vbeltevery60,000km(36,000miles);donotadjust60,000(36,000)Checkbrakefluidlevelatfront/rearandtopupifnecessary*)Checkoperationofbrakesystemandfreedomfromleaks;repair/renewitemsifnecessary*)Examinebrakepadsanddiscsforwear,renewifnecessary*)RenewthebrakefluidannuallyCheckclutchoperatingfluidlevelChangeclutchfluidevery40,000km(24,000miles)oratleastevery2years*)40,000(24,000)every2yearsChecktightnessofrearwheelstudsCheckrearwheelbearingplaybytiltingwheelCheckswingingarmbearings(zeroplay);adjustifnecessary*)Greasetheside(prop)standpivotCheckfunctionofside(prop)standcontactswitchCheckconditionofsparkplugsRenewsparkplugs*)TakeupslackatcylinderheadnutsCheck/adjustvalveoperatingclearancesCheckthrottlecableforfreemovement,abrasionandkinking;renewifnecessary*)CheckfreetravelinthrottlecableChecksynchronisationandeliminateanyleaks*)Finalinspectionwithroadsafetyandfunctionalcheck:–conditionoftyresandwheels,tyrepressures–lightsandsignallingequipment–telltaleandwarninglights–clutch,gearshift–handbrakeandfootbrake,steering–instruments–trialrunifnecessary*)ChargedasanadditionalitemBMWAGMotorcycleDivisionMaintenancescheduleR1100SOrderNo.01717654263UX-VS-2,3.99PrintedinGermanyCustomerLicenceplateNo.OrderNo.Mechanic’ssignatureBMWPre-deliverycheckCheckingtheshippingcratefordamageMotorcycle:–unpack–attachitemssuppliedloose–inspectfordamage–checkthatdeliveryiscomplete:toolsdocumentationkeyscorrectoptionalextrasFillandchargethebattery(markwithchargingdate)Checkengineoillevelwhencold;addoilifnecessaryCheckclutchoperatingfluidlevelandbrakefluidlevelsatfrontandrearCheckheadlightbeamangleandadjustifnecessaryCheckingtightnessofrearwheelstuds(complywithcorrecttighteningtorque)ChecktyrepressuresAddfuelFinalinspectionandfunctionalcheck:–clutch,gearshift–handbrake,f