![BMW R100R [118/168] Assembling transmission](/img/pdf.png)
BMW R100R [118/168] Assembling transmission
![BMW R100R [118/168] Assembling transmission](/views2/1121026/page118/bg76.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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CALCULATING THICKNESS OF SPACER RING FOR END PLAY NOTE If a paper gasket is used for the transmis sion cover seal this should be placed be low the measuring plate when performing this measurement Measure distance between ball bearing outer race and measuring plate using depth gauge BMW No 00 2 550 Actual distance size measured thickness oi mea suring plate Place measuring plate BMW No 23 3 650 onto the transmission housing Fix measuring plate in place with two bolts NOTE 9 3 ASSEMBLING TRANSMISSION NOTE Secure fastening screw with Loctite 270 Place guard plates 4 7 into the ball bear ing bores of the housing Heat transmission housing in the area of the bearing seats to approx 80 100 C Insert output shaft 5 and intermediate shaft 9 together with 3rd and 4th gear shift fork 10 Into housing with long guide end facing down CAUTION Insert oil baffle 8 and tighten with fasten ing screw 2 Install bearing block 12 into neutral posi tion Tighten fastening screws of bearing block to specified tightening torque Tighten shift lever 14 with fastening screw 13 Insert input shaft 11 Shift forks must not jam Insert 1 st 2nd and 5th gear shift fork 6 with the short guide ends facing each oth er and fix in place with shaft 3 9 18 Tightening torque Shift block mounting 24 Nm Permissible play when using old bearings 0 00 0 05 Permissible play when using new bearings 0 05 0 10 It is recommended to enter the calculated values in the table see example Calculate depth of ball bearing seat in housing cover size of cover EXAMPLE OF CALCULATION Input shaft Interm shaft Output shaft 1 Size of cover mm 15 35 15 75 15 35 2 Housing mm 7 25 7 30 7 30 Measuring plate mm 7 50 7 50 7 50 3 Total size of housing mm 14 75 14 80 14 80 4 Difference 1 3 mm 0 60 0 95 0 55 5 Average end play mm 0 05 0 05 0 05 6 Thickness of spacer incl oil baffle mm 4 Difference 5 Average end play 0 55 0 90 0 50 9 19
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