BMW R 1100 S EVO Betriebsanleitung

BMW AG Motorcycle Division

After Sales

R 1100 S

Repair Manual

Published by: © BMW AG Motorcycle Division

After Sales

UX-VS-2

permission.

Errors and omissions excepted; subject to technical amendment.

Produced in Germany 06/99

Introduction

This repair manual will help you to perform all the main maintenance and repair work correctly and efficient-

ly. It should be consulted regularly by workshop personnel as an addition to the practical and theoretical

knowledge obtained in Training School courses. It is a contribution towards achieving even higher Service

quality.

All information in both text and illustrations refers to motorcycles in standard condition or with genuine

BMW accessories installed, and not to motorcycles which have been modified in any way to depart from

the manufacturer’s specification.

●The repair manual is structured in the logical sequence of the work to be performed: Removal, Dis-

assembly, Repair, Assembly, Installation.

●The entire contents are divided into individual chapters, corresponding to the Construction Groups.

11 . 10

Chap. Page number within chapter

●Work to be performed during an Inspection is described in Group “00”. The various inspection routines

are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that

work can take place without interruption.

●Use of the BMW special tools needed for certain tasks is described in the work instructions.

If the need arises, repair instructions are also issued in the form of Service Information. This information is

of course incorporated into the next issue of the repair manual. We also recommend you to consult the

detailed illustrations on the Parts microfiches as an additional source of information.

BMW AG Motorcycle Division

After Sales

Published by: BMW AG, Sparte Motorrad

Hufelandstr. 6

D - 80937 München

permission.

Errors and omissions excepted; subject to technical amendment.

Produced in Germany

00 Maintenance and general instructions

11 Engine

12 Engine electrics

13 Fuel preparation and control

16 Fuel tank and lines

18 Exhaust system

21 Clutch

23 Gearbox

31 Front fork

32 Steering

33 Rear wheel drive

Contents

Group / Chapter

34 Brakes

36 Wheels and tyres

46 Frame

51 Equipment

52 Seat

61 General electrical equipment

62 Instruments

63 Lights

Group / Chapter

Order No. 01 71 7 654 263 UX-VS-2, 3.99 Printed in Germany

Customer Licence plate No.

Order No. Mechanic’s signature

BMW Inspection

at 1,000 km

(600 miles)

BMW Service

every 10,000 km

(6,000 miles)

BMW Inspection

every 20,000 km

(12,000 miles)

BMW

Annual Service

Read out the fault memory with the BMW MoDiTeC unit

Change the oil while at regular operating temperature and renew the oil filter

element

if motorcycle is used only for short journeys or at outside temperatures under 0°C, every 3 months,

but at least every 3,000 km (1,800 miles) *)

Change the oil in the gearbox while at regular operating temperature

at least every 2 years every

2 years

Change the oil in the rear wheel drive while at regular operating temperature

Clean the inductive sensor at the rear wheel

every 40,000 km (24,000 miles) or at least every 2 years *)

40,000

(24,000)

every

2 years

Renew fuel filter *)

normally every 40,000 km (24,000 miles), if fuel quality is poor every 20,000 km (12,000 miles) 40,000

(24,000)

Check battery acid level, if necessary add distilled water

Clean/grease battery poles if necessary

Renewing intake air cleaner element

in very dusty or dirty operating conditions, renew the intake air cleaner element

every 10,000 km (6,000 miles) or even more often if necessary *)

Renew Poly-V belt *)

Renew Poly-V belt every 60,000 km (36,000 miles); do not adjust 60,000

(36,000)

Check brake fluid level at front/rear and top up if necessary *)

Check operation of brake system and freedom from leaks;

repair/renew items if necessary *)

Examine brake pads and discs for wear, renew if necessary *)

Renew the brake fluid annually

Check clutch operating fluid level

Change clutch fluid

every 40,000 km (24,000 miles) or at least every 2 years *)40,000

(24,000)

every

2 years

Check tightness of rear wheel studs

Check rear wheel bearing play by tilting wheel

Check swinging arm bearings (zero play); adjust if necessary *)

Grease the side (prop) stand pivot

Check function of side (prop) stand contact switch

Check condition of spark plugs

Renew spark plugs *)

Take up slack at cylinder head nuts

Check/adjust valve operating clearances

Check throttle cable for free movement, abrasion and kinking; renew if necessary *)

Check free travel in throttle cable

Check synchronisation and eliminate any leaks *)

Final inspection with road safety and functional check:

– condition of tyres and wheels, tyre pressures

– lights and signalling equipment

– telltale and warning lights

– clutch, gear shift

– handbrake and foot brake, steering

– instruments

– trial run if necessary

*)Charged as an additional item

BMW AG Motorcycle Division

Maintenance schedule

R 1100 S

Order No. 01 71 7 654 263 UX-VS-2, 3.99 Printed in Germany

Customer Licence plate No.

Order No. Mechanic’s signature

BMW

Pre-delivery check

Checking the shipping crate for damage

Motorcycle:

– unpack

– attach items supplied loose

– inspect for damage

– check that delivery is complete: tools

documentation

keys

correct optional extras

Fill and charge the battery (mark with charging date)

Check engine oil level when cold; add oil if necessary

Check clutch operating fluid level and brake fluid levels at front and rear

Check headlight beam angle and adjust if necessary

Checking tightness of rear wheel studs

(comply with correct tightening torque)

Check tyre pressures

Add fuel

Final inspection and functional check:

– clutch, gear shift

– handbrake, foot brake

– lighting and signalling equipment, telltale lights, instruments

– check operation of optional extras, ABS

– trial run if necessary

Confirm pre-delivery check in Service and Technical Booklet

Final cleaning

Motorcycle handed over on:

BMW AG Motorcycle Division

Pre-delivery check

R 1100 S

00.1

Contents Page

Tightening torques ......................................................................................................................5

Table of consumables ..............................................................................................................11

00 Maintenance and general instructions

Tightening torques and Table of consumables

Pre-delivery check

Maintenance

00.2

Contents - Pre-delivery check Page

Pre-delivery check .....................................................................................................................13

General view of crated motorcycle ..................................................................................13

Checking the crate for damage ..........................................................................................14

In case of damage in Germany ...............................................................................................14

In case of damage in importer markets ..............................................................................14

Unpacking the motorcycle ....................................................................................................14

Installing remaining items on

motorcycle .....................................................................................................................................14

Inspecting motorcycle for damage ..................................................................................14

Checking that delivery is complete ..................................................................................14

Filling and charging the battery .........................................................................................15

Disengaging and raising the fuel tank .................................................................................15

Filling and charging the battery ..............................................................................................15

Checking engine oil level when cold, adding oil if necessary ...........................16

Checking clutch fluid level ....................................................................................................17

Checking brake fluid level .....................................................................................................17

Rear brake .......................................................................................................................................17

Front brake ......................................................................................................................................17

Checking headlight beam angle, adjusting if necessary .....................................18

Checking tightness of rear wheel studs ........................................................................18

Checking tyre pressures ........................................................................................................18

Final inspection and function check ...............................................................................19

Final cleaning ...............................................................................................................................19

Handing over the motorcycle ..............................................................................................19

Pre-delivery check

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