![BMW R100R [105/168] Exhaust system](/img/pdf.png)
BMW R100R [105/168] Exhaust system
![BMW R100R [105/168] Exhaust system](/views2/1121026/page105/bg69.png)
Содержание
- Contents 2
- Introduction 3
- Contents 6
- Delivery inspection 6
- Fitting out motor cycle 6
- Affixing helmet sticker 7
- Contents of dish 7
- Documentation 7
- Fitting out motor cycle 7
- Installing rear view mirrors 7
- Installing windshield 7
- Tightening handlebar controls 7
- Caution 8
- Charging batteries 8
- Checking correcting tire infla tion pressure 8
- Checking lighting and signal sys tem 8
- Checking rear wheel bolts are tight 8
- Delivery inspection 8
- Filling battery with electrolyte 8
- Removing battery 8
- Store batteries away from the reach of children 8
- Caution 9
- Checking brake fluid 9
- Checking topping up brake fluid 9
- Final visual inspection for leaks on 9
- Maintenance and inspection 9
- Performing operational check 9
- Topping up brake fluid 9
- Contents 10
- Contents 11
- Engine and transmission 11
- Bmw maintenance and inspection schedule 12
- Caution 12
- Changing brake fluid at least once a year 12
- Running gear 12
- Tightening cylinder head 12
- Tightening cylinder head nuts inspection i 12
- Vessel 12
- A checking end play 13
- Adjusting valve clearance in spection i ii iii 13
- B adjusting end play 13
- Caution 13
- Checking adjusting end play of rocker arm inspection iii 13
- Valve clearance 13
- Bright 14
- Carbon fouled 14
- Caution 14
- Compression pressure constant 14
- Compression pressure on both cylinders 14
- Compression pressure too low 14
- Condition of spark plugs 14
- Evenly too low 14
- Normal 14
- Oil fouled 14
- Spark plugs 14
- Testing compression pres sure 14
- Worn electrode 14
- Caution 15
- Checking electrode gap with feeler gauge or spark plug gauge 15
- Checking spark plugs and elec trode gap inspection ii 15
- Electrode gap 15
- Electrode gap too small 15
- Electrode gap too wide 15
- Renewing air filter 2 cleaning fuel cocks 15
- A checking firing point 16
- Adjusting clutch play 16
- B setting firing point 16
- Checking adjusting 16
- Checking adjusting firing 16
- Checking adjusting firing point static 16
- Checking clutch play at hand le ver 16
- Cleaning carburettor 16
- Clutch play inspection i iii 16
- Erm tr 16
- Float housing inspection 11 111 16
- Peon i 1 16
- Some b 16
- Warning 16
- Wonl i to chi t trpn ci 16
- A checklng firing point 17
- B setting firing point 17
- Basic setting of carburettor 17
- Checking setting firing point dynamic 17
- Synchronising carburet tors adjusting cables inspection i ii iii 17
- Final adjustment of the throttle cables 18
- Synchronising carburettors with co measurement 18
- Synchronising carburettors without co measurement 18
- Synchronizing carburettors with co measurement for pas 18
- Caution 19
- Changing oil and oil filter 19
- Changing oil filter 19
- Changing oil in transmis 19
- Ii i 1 b enr l rum bcli th 81 in uhl in i al i dtn erun i dei i ode i stuh ce 1 nr 11 19
- In engine inspection i ii iii 19
- Sion inspection i iii 19
- Tl oxi 19
- V pouring in engine oil 19
- Changing oil in telescopic fork inspection i iii 20
- Changing transmission oil in rear wheel drive inspection i iii 20
- Checking brake pad for wear 21
- Checking front brake pads for wear renewing inspection iii 21
- Installing brake pads gs 21
- Removing brake pads gs 21
- A checking brake fluid level 22
- Caution 22
- Check1ng topping up brake 22
- Checking brake discs inspection ii 22
- Checking thickness of brake 22
- Fitting front brake pads r100r 22
- Fluid level inspection i 111 22
- Removing 22
- Warning 22
- B topping up brake fluid level 23
- Bleeding front wheel brake sys tem with bleeder 23
- Bleeding front wheel brake system 23
- Caution 23
- Changing brake fluid 23
- A removing rear wheel e 24
- Bleeding front wheel brake us ing handbrake lever 24
- Caution 24
- Checking rear brake pads for wear renewing brake shoe if necessary inspection iii 24
- Renewing rear brake shoe 24
- U checking rear brake pads for wear 24
- B renewing rear brake shoe 25
- C checking brake drum for wear 25
- Caution 25
- Checking adjusting foot brake lever play inspection iii 25
- Checking foot brake lever play 25
- Checking front wheel bearing inspection iii 25
- Checking rear wheel for tilt play inspection iii 25
- D installing rear wheel adjusting foot brake lever play 25
- Warning 25
- Adjusting steering bearing clea rance mod 1 r100r 26
- Adjusting steering bearing play 26
- Battery faults 26
- Battery maintenance 26
- Caution 26
- Checking adjusting steer ing bearing play inspection iii 26
- Checking steering bearing play 26
- Greasing clutch cable nip ples inspection ii iii 26
- S adjusting swing arm bear ing play inspection iii 26
- Warning 26
- Battery care when motor cycle stored out of use 27
- Caution 27
- Charging batteries 27
- Check of condition 27
- Checking nuts and bolts for tight fit inspection i ii iii 27
- Checking topping up electrolyte level of battery inspection 111 27
- Commissioning battery 27
- Conscientiously perform ing final inspection with check of road operation al safety inspection i ii iii 27
- Functional check 27
- Tyre inflation pressures bar 27
- Contents 29
- As a function of outside temperature 30
- Engine oil viscosity diagram 30
- Fuel oils and lubricants all models 30
- Adhesives and locking devices 31
- Applicatlon term 31
- Brake system 31
- Engine 31
- Instance of use i order no quantity 31
- Lubricants 31
- Operating materials 31
- R 100 gs 31
- R 100 gs iltloil 31
- R 100 r 31
- Rear wheel drive 31
- Sealants 31
- Service data r 80 gs 31
- Telescopic fork 31
- Electrics 32
- Engine 32
- Front wheel 32
- Rear wheel 32
- Swing arm 32
- Telescopic fork 32
- Tightening torques nm all models 32
- Transmission 32
- Adjusting headlamp 4 7 33
- Contents 33
- Disassembling and assembling installing display panei____ 4 1 33
- Dismantling and installing speedometer 33
- Removal display panel with ignition lock 1 33
- Removing and installing handlebar controls 2 33
- Removing and installing headlamp 4 33
- Removing and installing rear light 8 33
- Removing and installing speedometer 4 9 33
- Removing and installing turn signals 8 33
- Revolution counter r 100r 4 0 33
- Testing operation of alternator regulator and diode plate 4 2 33
- Removing and installing head light pd 35
- Removing and installing headlamp 35
- Removing flashing turn indicators with holders 35
- Removing side section of instrument car rier 36
- Removing the instrument carrier 36
- Installing side section of instrument car rier 37
- Installing the headlight installing the instrument carrier installing the speedometer 37
- Installing flashing turn indicator with hol der 38
- Installing the windscreen 38
- Removing and installing the head light 1991 models 38
- Installing the headlight 39
- Installing the instrument carrier 39
- Removing the headlight 39
- Removing the ignition switch 39
- Removing the revolution counter 39
- Installing the ignition switch 40
- Installing the revolution counter 40
- Adjusting headlamp 41
- Adjusting headlamp with beam adjuster 41
- Adjusting headlamp without beam adjuster 41
- Obere gabelbrücke muß sich leicht auf standrohre lenkrohr aufschieben las sen 41
- Removing and installing head light r 100r 41
- Removing and installing rear light 42
- Removing and installing speedometer 42
- Removing and installing turn signals 42
- Disassembling and assembling installing display panel 43
- Dismantling and installing spee dometer revolution counter r 100r 43
- Removal display panel with igni tion lock 43
- Caution 44
- Quick test of alternator and regulator 44
- Removing and installing handle bar controls 44
- Testing operation of alterna tor regulator and diode plate 44
- Testing regulator 44
- Caution 45
- Removing and installing bat tery 45
- Removing and installing fuse box 45
- Removing testing and install ing relays 46
- Testing diode of starter relay 46
- Testing operation of light relay c 46
- Testing operation of starter relay b 46
- Testing operation of turn signal relay a 46
- Removing and installing ignition control unit 47
- Removing and installing regu lator 47
- Removing testing and installing ignition coil 47
- Testing resistances of ignition coil 47
- Ing diode plate 48
- Installed 48
- Removing and installing ignition 4 9 replacing carbon brushes 48
- Removing testing and install 48
- Trigger 48
- D testing stator winding for short to ground 49
- Removing alternator 49
- Removing testing disassem bling and assembling alterna tor 49
- Testing alternator 49
- Testing exciter winding on slip rings 49
- Testing rotor for short to ground 49
- Testing stator winding 49
- Assembling stator 50
- Installing alternator 50
- Testing starter 50
- Testing with amperemeter disassembling stator 50
- Testing with voltmeter 50
- Disassembling starter 51
- Removing disassembling assem bling and installing starter 51
- Removing starter 51
- Replacing carbon brushes 51
- Assembling starter 52
- Installing 52
- Removing and installing switch for idle display 52
- Cable harness 53
- Removing and installing clutch switch 53
- Removing and installing engine 53
- Removing and installing front stop light switch 53
- Removing and installing horn 53
- Removing and installing rear stop light switch 53
- Removing and installing chassis cable harness section 54
- Removing and installing rear cable harness section 54
- Troubleshooting 55
- Troubleshooting ignition system 55
- Troubleshooting alternator 56
- Ye s y 57
- Brake system 58
- Contents 59
- Installing front wheel brake 4 59
- Installing rear wheel brake 0 59
- Removing front wheel brake 59
- Removing rear wheel brake 59
- Troubleshooting 3 59
- Caution 60
- Removing brake caliper 60
- Removing brake disc 60
- Removing front wheel 60
- Warning 60
- Assembling brake caliper gs 61
- Caution 61
- Disassembling brake caliper gs 61
- Caution 62
- Removing and installing front brake pads r100r 62
- Stripping down r 100r brake cali 62
- Assembling r 100r brake caliper removing brake line 63
- Caution 63
- Caution 64
- Disassembling and assembling brake fluid reservoir and mas ter brake cylinder 64
- Removing brake fluid reservoir and master brake cylinder 64
- Caution 65
- Installing brake caliper 65
- Installing brake disc 65
- Installing front wheel brake 65
- Installing master brake cylinder and brake fluid reservoir 65
- Removing rear wheel brake 66
- 5 8 5 9 67
- Pay attention to wear limits 67
- Removing brake lever removing brake shoes 67
- Caution 68
- Installing brake key and brake lever 68
- Installing brake shoes 68
- Installing foot brake lever 68
- Installing rear wheel 68
- Removing foot brake lever 68
- Adjusting foot brake lever play 69
- Handbrake 69
- Iwilililiiiiiis 69
- Troubleshooting 69
- Suspension 70
- Contents 71
- Disassembling and assembling grip units 6 71
- Removing and installing disassembling and assembling tele 71
- Removing front wheel and replacing wheel bearings 71
- Removing handlebars 6 71
- Scopic fork 71
- Contents 72
- Examining rims for runout centering 5 72
- Installing front wheel 0 72
- Installing handlebars 6 9 72
- Installing rear wheel 6 8 72
- Installing rear wheel drive 6 6 72
- Installing spring strut 7 72
- Measuring track alignment 6 1 72
- Removing and installing disassembling and assembling rear 72
- Removing and installing spokes 4 72
- Removing disassembling and assembling rear spring strut 6 8 72
- Removing rear wheel 6 3 72
- Static wheel balancing 7 72
- Wheel drive 6 2 72
- Wheel swing arm 4 72
- Caution 73
- Installing wheel bearings 73
- Removing front whee replacing wheel bea 73
- Assembling right grip unit 74
- Disassembling and assem bling grip units 74
- Disassembling right grip unit 74
- Removing handlebars 74
- Assembling left grip unit 75
- Disassembling left grip unit 75
- 6 0 6 1 76
- Removing and installing disassembling and assem bling telescopic fork 76
- Removing telescopic fork 1988 models 76
- Removing telescopic fork r 100 r 76
- Removing the telescopic fork 1991 mod els 76
- Caution 77
- Disassembling telescopic fork gs 77
- Removing and installing shaft seal and sliding bush in sliding tube 78
- Removing the fixed tube 79
- Stripping down telescopic fork r 100 r 79
- Stripping down the tlxed tube 79
- Caution 80
- Damper components 80
- Examine parallelisms of the stanchions 80
- Examining bottom fork bridge 80
- Measuring telescopic fork align ment 80
- Assembling telescopic fork gs 81
- Assembling telescopic fork r 100 r 81
- 6 2 6 3 82
- Assembling stanchions 82
- I i iii 83
- Examining front frame section 84
- Caution 85
- Installing telescopic fork 85
- Mod 91 and r 100r 85
- Caution 86
- Installing handlebars 86
- 6 2 6 3 87
- Caution 87
- Installing front wheel 87
- Measuring track align ment 87
- Caution 88
- Example 88
- Misalignment 88
- Removing rear wheel 88
- Slacken 4 wheel bolts 1 88
- A front wheel rim 89
- B rearwheelrim 89
- Caution 89
- Centre rim 89
- Examining rims for runout centering 89
- Examining rims for vertical and lateral runout 89
- Installing spokes 89
- Removing and installing spokes 89
- Removing spokes 89
- Caution 90
- Centering lateral runout 90
- Static wheel balancing 90
- 6 0 6 1 91
- Caution 91
- Disassembling and assembling rear spring strut 91
- Removing and installing rear spring strut 91
- Removing disassembling and assembling rear spring strut 91
- Warning 91
- Caution 92
- Removing and installing disassembling and assem bling rear wheel drive 92
- Removing rear wheel drive 92
- Removing stripping and assem bling the input bevel pinion 92
- Removing the input bevel pinion 92
- 6 4 6 5 93
- Installing the needle roller bearing 93
- Removing the needle roller bearing 93
- Stripping down the input bevel pinion 93
- Assembling the input bevel pinion installing the input bevel pinion 94
- Caution 94
- Adjusting tooth backlash 95
- Installing crown wheel 95
- Shimming the crown wheel 95
- Caution 96
- Checking tooth contact pattern 96
- Installing the housing cover 96
- Shimming the housing cover 96
- Caution 97
- Installing swing arm and adjust ing bearing play 97
- Removing and installing disassembling and assem bling rear wheel swing arm 97
- Removing and installing taper roller bearings 97
- Installing rear wheel drive 98
- Installing spring strut 98
- Caution 99
- Frame attachments 99
- Installing rear wheel 99
- Contents 100
- Removing and installing rear mudguard 101
- Removing disassembling and assembling installing rear frame section 101
- Removing rear frame section 101
- Removing rear mudguard 101
- As sembled and installed 102
- Disassembling rear frame sec tion 102
- Removing and installing cylinder guard 102
- Removing and installing side stand gs 102
- Removing cylinder guard 102
- Removing side stand 102
- Caution 103
- Removing and disassembling foot rests 103
- Removing and installing kickstand 103
- Removing disassembling and assembling installing foot rests 103
- Removing kickstand 103
- Installing foot rests 104
- Removing air filter box 104
- Removing and installing air fil ter box with pas additionally 104
- Removing and installing air filter box 104
- Exhaust system 105
- Removing and installing battery mount 105
- Removing and installing steering lock 105
- Removing battery mount 105
- Contents 106
- Removing and installing exhaust system 8 106
- Removing and installing exhaust system 107
- Removing main silencer gs 107
- Removing main silencer r100r 107
- Installing front silencer and ex haust manifold 108
- Installing main silencer gs 108
- Installing main silencer r100r 108
- Removing front silencer and ex haust manifold 108
- Assembling transmission 8 110
- Contents 110
- Disassembling transmission 9 110
- Installing transmission 2 110
- Removing transmission 9 110
- Troubleshooting transmission 5 110
- Removing transmission 111
- Caution 112
- Disassembling transmis sion 112
- Removing disassembling and as sembling transmission cover 112
- Warning 113
- Assembling bearing block 114
- Caution 114
- Disassembling bearing block 114
- Removing and installing kick starter 114
- Removing bearing block for shift discs 114
- Assembling input shaft 115
- Removing and disassembling input shaft 115
- Removing output and intermedi ate shafts 116
- Assembling output shaft 117
- Disassembling and assembling in termediate shaft 117
- Replacing radial pivot bearing and sealing ring for shift lever 117
- Replacing radial seal for input shaft 117
- Replacing roller bearing of in put shaft 117
- Assembling transmission 118
- Calculating thickness of spacer 118
- Caution 118
- Example of calculation 118
- Ring for end play 118
- 9 0 9 1 119
- Installing transmission 120
- 9 4 9 5 121
- Disassembling and assembling gear shift linkage 121
- Installing shift lever 121
- Troubleshooting transmission 121
- Clutch 122
- Contents 123
- Removing and installing clutch 0 123
- Troubleshooting 10 123
- Caution 124
- Installing clutch 124
- Removing and installing clutch 124
- Removing clutch 124
- Caution 125
- Gijdddetwbbiisib 125
- Troubleshooting 125
- Contents 127
- Disassembling engine 11 8 127
- Fuel preparation 11 127
- Removing engine 11 6 127
- Troubleshooting shed system 11 5 127
- Assembling engine 11 2 128
- Fuel preparation 128
- Installing engine 11 3 128
- Removing and disassembling assembling and installing oil cooler 11 5 128
- Removing and disassembling fuel tap 128
- Removing and installing bowden cable for cold start device 128
- Troubleshooting engine 11 6 128
- Are installed 129
- Caution 129
- Installed 129
- Removing and installing bowden cables for throttle control 129
- Removing carburettor 129
- Disassembling carburettor 130
- Removing nozzle set 130
- Assembling carburettor 131
- Annex to section 11 132
- Caution 132
- Removing shed fuel system usa 132
- Caution 133
- Shed system 133
- System diagram of shed fuel sys tem usa 133
- Troubleshooting 133
- Removing engine 134
- Disassembling cylinder head 135
- Disassembling engine 135
- Examining cylinder head 135
- Examining valves and valve guides for wear 135
- Removing cylinder head 135
- Removing valves 135
- Checking valve guide for wear 136
- Measuring valve tilt angle at combustion chamber end 136
- Measuring valve tilt angle at rocker end 136
- Caution 137
- Reaming out valve guide 137
- Replacing valve guides 137
- Warning 137
- Caution 139
- Examining piston and cylinder 139
- Removing conrod 139
- Removing cylinder 139
- Caution 140
- Examining and repairing conrod 140
- Caution 141
- Examining conrod for parallel ism and twisting 141
- Assembling oil pump 142
- Examining oil pump 142
- Removing oil pump 142
- Removing seal 142
- Replacing radial seal for crank shaft seal 142
- Installing seal 143
- Removing chain box cover 143
- Caution 144
- Examining camshaft 144
- Removing camshafts 144
- Replacing radial seal for crank shaft seal 144
- Caution 145
- Determining crankshaft bearing play 145
- Removing crank shaft 145
- Caution 146
- Removing and installing bypass valve 146
- Removing and installing vent cover 146
- Removing crankshaft bearing 146
- Removing crankshaft bearing bush from bearing cover 146
- Removing crankshaft bearing bush from engine housing 146
- Removing oil sump and intake bell 146
- Assembling engine 147
- Caution 147
- Installing crank shaft bearing bush in engine housing 147
- Installing new crankshaft bear ing bush in bearing cover 147
- Caution 148
- Examining conrod bearing play 148
- Installing crankshaft 148
- Caution 149
- Example 149
- Installing camshaft 149
- Attaching chain box cover 150
- Caution 150
- Installing oil pump 150
- Attaching cylinder head 151
- Caution 151
- Installing cylinder 151
- Caution 152
- Installing engine 152
- Installing intake bell and oil sump 152
- Caution 153
- Removing and disassem bling assembling and in stalling oil cooler 153
- Removing and disassembling oil cooler 153
- Troubleshooting engine 154
- Technical data 155
- Consumption 156
- Conversion table 156
- Pressure 156
- Technical data 156
- Torque 156
- Value in 1 100km 156
- Value in kg kw 156
- Volume 156
- Weight 156
- Weight per unit power 156
- Consumption 157
- Conversion table 157
- Length 157
- Measuring main bearing shells 157
- Model chassis no odometer reading 157
- Order no________________________________ annex to ga no 157
- Pressure 157
- Report for measuring crankshaft main bearing play 157
- Technical data technical data 157
- Torque 157
- Volume 157
- Weight 157
- Weight per unit power 157
- As a function of outside temperature 158
- Engine oil viscosity diagram 158
- Fuel oils and lubricants 158
- Technical data 158
- Alternator 159
- Diode plate 159
- Electrical system 159
- General electrical system 159
- Ignition coll 159
- Ignition trigger 159
- Lights 159
- Spark plugs 159
- Starter 159
- Technical data 159
- Voltage regulator 159
- Brake system 160
- Front wheel 160
- Rear wheel drive 160
- Running gear 160
- Technical data 160
- Telescopic fork 160
- Clutch 161
- Driven flange 161
- Foot shift lever shaft 161
- Input shaft 161
- Intermediate shaft 161
- Output shaft 161
- Rear wheel suspension 161
- Running gear 161
- Technical data r80gs r 100 gs pd r 100 r 161
- Technical data r80gs r100gs pd r 100 r 161
- Wheels and tires 161
- Engine lubrication system 162
- Ou pump 162
- Technical data r80gs r 100 gs pd r 100 r 162
- Technical data r80gs r100gs pd r 100 r 162
- 12 4 12 5 163
- Camshaft 163
- Rocker arm 163
- Technical data 163
- Technical data r80gs r 100gs pd r 100 gs pd 163
- Valve guides 163
- Valve seat ring 163
- Valve spring 163
- Alternator end flywheel end 164
- Conrod and bearings 164
- Crankshaft and bearings 164
- Engine 164
- Main bearing journals dia mm 164
- Technical data 164
- Technical data r80gs r 100 gs pd r 100 r 164
- Cylinder 165
- Engine 165
- Piston pin 165
- Piston rings 165
- Technical data r80gs r100 gs pd r100 r 165
- Technical data r80gs r100gs pd r 100 r 165
- Carburettor 166
- Dimensions 166
- Fuel system 166
- General technical data 166
- Kw r 100gs pd r100r 166
- Performance 166
- Technical data 166
- Technical data r 80 gs 166
- Engine electrics 167
- Propeller shaft 167
- Technical data 167
- Technical data r80gs r100gs pd r100r 167
- Tightening torques 167
- Tightening torques nm 167
- Transmission 167
- Technical data r80gs r100gs po r100r 168
- Telescopic fork 168
- Tightening torques nm 168
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8 EXHAUST SYSTEM 7 8 REMOVING AND INSTALLING BATTERY MOUNT 7 9 REMOVING AND INSTALLING STEERING LOCK REMOVING BATTERY MOUNT NOTE When removing the battery mount ensure that the two bottom damper elements 4 are screwed in with a headless set screw the two top damper elements 3 are secured with a locking nut 2 Remove seat Remove battery Remove battery mount 1 in the order shown in the drawing The battery mount is Installed in the reverse order by analogy to removal Use screwdriver to lift off cover plate 3 Insert key 2 into lock Turn counter clockwise asfar asthe stop Withdraw locking cylinder 1 The steering lock is installed in the reverse order by analogy to removal 7 12
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