BMW R100R [2/168] Contents

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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Contents 0 Introduction 1 Completing the motorcycle and pre delivery check 2 Maintenance and inspection 3 Operating media and servicingdata 4 Electrics 5 Brake system 6 Suspension 7 Frame attachments 8 Exhaust system 9 Gearbox 10 Clutch 11 Engine 12 Technical data 0 3