Bmw R1100S Service Repair Manual-21215B320092.pdf -Bookmark created by https://wimanual.com Repair Manual Introduction Contents Maintenance schedule Pre-delivery check 00 Maintenance and general instructions Tightening torques Table of consumables Pre-delivery check General view of crated motorcycle Checking the crate for damage In case of damage in Germany In case of damage in importer markets Unpacking the motorcycle Installing remaining items on motorcycle Inspecting motorcycle for damage Checking that delivery is complete Filling and charging the battery Disengaging and raising the fuel tank Filling and charging the battery Checking engine oil level when cold, adding oil if... Checking clutch fluid level Checking brake fluid level Rear brake Front brake Checking headlight beam angle, adjusting if necess... Checking tightness of rear wheel studs Checking tyre pressures Final inspection and function check Final cleaning Handing over the motorcycle Maintenance Key to maintenance intervals Reading out MoDiTeC fault memory (Inspections I, II, III and IV) Changing engine oil, replacing oil filter element (Inspections I, II, III and IV) Changing oil in gearbox (Inspections III and IV) or every 2 years at the latest Changing oil in rear wheel drive; cleaning inducti... (Inspections I, III and IV) Every 40 000 km (24 000 miles) or every 2 years at... Replacing fuel filter (Inspection III) In normal operating conditions every 40 000 km (24... Checking battery fluid level and topping up if nec... (Inspections III and IV) Replacing intake air filter element (Inspection III) In very dirty and dusty operating conditions, repl... Replacing Poly-V belt (every 60 000 km (Inspection III) Poly-V belt adjusting procedure: Checking brake fluid level Front brake Rear brake Checking brake pads and discs for wear (Inspections II and III) Checking front brake pad wear Checking rear brake pad wear Checking brake disc wear Replacing brake pads, front brake Replacing brake pads, rear brake Changing brake fluid and bleeding brake system Change the brake fluid annually (Inspection IV) Bleeding front brake circuit Additional information for [ABS] Bleeding rear brake circuit Checking clutch fluid level (Inspections I, II and III) Changing the clutch fluid (Inspections III and IV) Every 40 000 km (24 000 miles) or every 2 years at... Checking tightness of rear wheel studs (Inspection I) Checking rear wheel bearing play by tilting wheel (Inspection III) Checking swinging arm bearings, adjusting if neces... (Inspections I and III) Greasing the side stand pivot (Inspections I, II and III) Checking function of side stand switch (Inspections I, II, III and IV) Checking (Inspection II) check Tightening cylinder heads (Inspection I) Checking (Inspections I, II and III) Checking throttle cable for ease of movement, abra... (Inspections I, II, III and IV) Final inspection with road safety and functional c... (Inspections I, II, III and IV) Road safety check Roadworthiness check 11 Engine Cutaway drawing of engine Lubricating-oil circuit Cooling-oil circuit Removing engine Disassembling engine Removing cylinder head cover Locking the engine at TDC Firing TDC Removing and installing chain tensioner Work instructions, timing-chain tensioner Removing valve gear holder Disassembling Removing cylinder head Disassembling, checking, repairing and reassemblin... Removing and installing valves Removing valve stem seals Checking valves for wear Remachining valve seat Checking and repairing cylinder head Checking valve guide for wear Replacing valve guides Installing valve and valve stem seal Removing cylinder Removing and disassembling piston Checking pistons and cylinders Assembling pistons Removing and installing conrod Removing and installing alternator mount cover wit... Removing alternator mount cover Replacing radial shaft seal in alternator mount co... Removing auxiliary shaft drive Removing oil pump Removing radial shaft seal from crankshaft with en... Disassembling crankcase Removing crankshaft, auxiliary shaft and timing ch... Removing and installing oil intake strainers Replacing oil level sight glass Removing and installing oil thermostat Removing conrods Checking conrods Measuring crankshaft bearing play Measuring radial bearing play Installing main bearings Measuring axial bearing play Measuring big end bearing play Assembling engine Installing conrods Installing crankshaft Installing timing chain tensioning and slide rails... Installing auxiliary shaft Assembling engine block Installing radial shaft seals on crankshaft Installing the crankshaft-end radial shaft seal Installing the clutch-end radial shaft seal Installing clutch housing Installing oil pump Installing auxiliary shaft drive Installing piston Installing cylinder Installing cylinder head Adjusting valve clearances Installing right cylinder head Adjustment specification Installing left cylinder head Adjustment specification Installing alternator mount cover Installing magnetic gate Timing the ignition Installing alternator Installing engine 12 Engine electrics Removing and installing coil and ignition leads Checking ignition coil resistance Removing and installing alternator Poly-V belt adjusting procedure: Disassembling Checking alternator Checking armature for short to ground (earth) Disassembling (Option 50 A) Checking alternator Checking armature for short to ground (earth) Removing and installing starter motor Disassembling Replacing carbon brushes Checking starter motor Checking starter relay Removing and installing magnetic gate Timing the ignition 13 Fuel preparation and control Removing and installing air filter housing Removing and installing throttle- valve stub pipe Removing and installing throttle-valve potentiomet... Removing and installing Motronic control unit 16 Fuel tank and lines Removing and installing fuel tank Removing and installing fuel filter, fuel pump and... Removing and installing fuel filter Removing and installing fuel pump and fuel level s... Checking fuel pump pressure Removing and installing fuel distributor and press... 18 Exhaust system Removing and installing exhaust system Removing and installing silencer (muffler) Removing and installing exhaust manifolds 21 Clutch Removing and installing clutch hydraulic line Removing and installing clutch slave cylinder Filling Removing and installing clutch Removing clutch Installing clutch 23 Gearbox Removing and installing gear-shift lever Removing gearbox Replacing the shaft sealing rings in the gearbox h... Replacing input shaft sealing ring at input end Replacing output shaft sealing ring Replacing input shaft sealing ring at output end Replacing shaft sealing ring for selector drum Replacing sealing ring for selector shaft Disassembling gearbox Removing gearbox housing Removing selector drum Disassembling Removing gearbox shafts Replacing grooved ball bearing on intermediate sha... Disassembling Disassembling input shaft Assembling input shaft Disassembling Disassembling output shaft Assembling output shaft Checking endplay Checking Checking Checking Checking Checking Shimming selector shaft Assembling gearbox Installing input, output and intermediate shafts Installing selector shaft Installing selector drum Installing gearbox housing 31 Front fork Removing and installing telescopic fork Removing and installing telescopic fork Removing and installing ball joint in slider tube ... Removing and installing ball joint in fork bridge Disassembling Disassembling telescopic fork Assembling telescopic fork Measuring telescopic fork Examining slider tube bridge and fork bridge Checking runout of fixed tube Checking runout of slider tube Removing and installing leading link Disassembling Removing and installing front suspension strut 32 Steering Removing and installing left handlebar fitting Removing and installing right handlebar fitting Removing and installing handlebar Removing and installing Bowden- cable divider, Bow... Disassembling Bowden-cable divider 33 Rear wheel drive Removing, disassembling, reassembling and installi... Removing rear wheel drive Removing input bevel pinion Disassembling input bevel pinion Removing needle roller bearing for input bevel pin... Installing needle roller bearing for input bevel p... Assembling input bevel pinion Installing input bevel pinion Removing and disassembling crown wheel Assembling Checking Checking tooth contact pattern Shimming housing cover Installing housing cover Installing sliding element Removing and installing rear swinging arm Removing rear swinging arm Removing and installing taper roller bearing Removing and installing flexible gaiter Removing drive shaft Checking universal joint for wear Installing drive shaft Installing rear swinging arm Installing rear wheel drive Removing and installing suspension strut 34 Brakes Removing and installing front brake caliper Disassembling and assembling front brake caliper Disassembling front brake caliper Assembling front brake caliper Removing and installing rear brake caliper Disassembling and assembling rear brake caliper Disassembling rear brake caliper Assembling rear brake caliper Removing and installing front brake disc Removing and installing rear brake disc Removing and installing front ABS sensor Adjusting front ABS sensor gap Marking sensor wheel Checking and adjusting sensor gap Removing and installing rear ABS sensor Adjusting rear ABS sensor gap Marking sensor wheel Checking and adjusting sensor gap Removing and installing rear brake master cylinder... Checking and adjusting play of piston rod Removing and installing footbrake lever Removing and installing ABS unit Removing the ABS unit Installing the ABS unit Removing and installing ABS relay and relay socket... Removing ABS relay Installing the ABS relay Removing ABS relay socket Installing the ABS relay base Removing and installing brake line Removing and installing front brake line Removing and installing rear brake line 36 Wheels and tyres Removing and installing front wheel Removing front wheel Installing front wheel Removing and installing wheel bearings Removing and installing rear wheel Static balancing of front and rear wheels Checking front 46 Frame Exploded view of fairing sections Removing and installing fairing Removing and installing side panels Removing and installing tank trim Removing and installing fairing Removing and installing rear side panels Removing and installing tail section Removing and installing rear mudguard Removing and installing number-plate carrier Removing and installing front mudguard Removing and installing fairing bracket Removing and installing front frame Removing and installing main frame Removing and installing frame tail section Removing and installing side stand Checking running gear Measuring wheel track offset 51 Equipment Removing and installing ignition switch Removing and installing ignition Removing and installing lock barrel Drilling out lock barrel Removing and installing dualseat lock Removing and installing lock barrel for fuel tank ... Drilling out lock barrel 52 Seat Removing and installing seat 61 General electrical equipment Relay positions (central electrical equipment box)... Fuse assignments Left fuse box Right fuse box Frame wiring harness Wiring harness View from left Wiring harness View from right 62 Instruments Removing and installing instrument panel Disassembling and assembling instrument panel 63 Lights Removing and installing headlight Adjusting headlight . Notice: This is a preview not fully updated, please download the full version at https://wimanual.com