Name: BMW Motorrad R 100 GS
Brand: BMW Motorrad
Rating: 5 (1 reviews)

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Contents2
Summary of Main Groups4
Fitting out Motor Cycle and Delivery Inspection5
Fitting out Motor Cycle7
Installing Windshield7
Affixing Helmet Sticker7
Tightening Handlebar Controls7
Delivery Inspection8
Removing Battery8
Filling Battery with Electrolyte8
Charging Batteries8
Maintenance and Inspection9
Checking/Topping up Brake Fluid9
Performing Operational Check9
Final Visual Inspection for Leaks on9
Running Gear12
Tightening Cylinder Head Nuts12
Checking/Adjusting End Play of Rocker Arm13
Adjusting Valve Clearance13
Testing Compression Pressure14
Spark Plugs14
Compression Pressure too Low14
Bright14
Renewing Air Filter15
Cleaning Fuel Cocks15
Electrode Gap15
Checking Spark Plugs and Electrode Gap15
Cleaning Carburetors Float Housing16
Checking/Adjusting Clutch Play16
Checking/Adjusting Firing Point16
Synchronising Carburetors Adjusting Cables17
Setting Firing Point17
Synchronising Carburetors Without CO Measurement18
Synchronising Carburetors with CO Measurement18
Final Adjustment of the Throttle Cables18
Changing Oil and Oil Filter in Engine19
Changing Oil in Transmission19
Changing Oil Filter19
Pouring in Engine Oil19
Changing Transmission Oil in Rear Wheel Drive20
Changing Oil in Telescopic Fork20
Checking Front Brake Pad for Wear/Renewing21
Renewing Brake Pads GS21
Installing Brake Pads GS21
Checking Brake Discs22
Checking/Topping up Brake Fluid Level22
Removing/Fitting Front Brake Pads22
Checking Thickness of Brake Discs22
Changing Brake Fluid23
Bleeding Front Wheel Brake System23
Bleeding Front Wheel Brake System with Bleeder23
Checking Rear Barke Pads for Wear/Renewing Brake Shoe24
Bleeding Front Wheel Brake Using Handbrake Lever24
Checking Rear Brake Pads for Wear24
Renewing Rear Brake Shoe24
Checking/Adjusting Foot Brake Lever Play25
Checking Rear Wheel for Tilt Play25
Checking Front Wheel Bearing25
Adjusting Foot Brake Lever Play25
Checking/Adjusting Steering Bearing in Play26
Greasing Clutch Cable Nipples26
Adjusting Swing Arm Bearing Play26
Battery Maintenance26
Checking Nuts and Bolts for Tight Fit27
Commissioning Battery27
Fuel, Oil and Lubricants and Service Data for Maintenanec28
Engine Oil Viscosity Diagram30
Operating Materials31
Lubricants31
Sealants31
Service Data31
Electrics32
Removing and Installing Headlamp35
Removing and Installing Headlight35
Removing Side Section of Instrument Carrier36
Removing the Speedometer36
Removing the Instrument Carrier36
Removing the Headlight36
Installing the Headlight37
Installing the Instrument Carrier37
Installing the Speedometer37
Installing Flashing Turn Indicator with Holder38
Installing the Windscreen38
Removing the Windscreen38
Installing the Ignition Switch40
Installing the Revolution Counter40
Tachometer40
Adjusting Headlamp41
Adjusting Headlamp Without Beam Adjuster41
Adjusting Headlamp with Beam Adjuster41
Removing and Installing Turn Signals42
Removing and Installing Rear Light42
Removing and Installing Speedometer42
Removal Display Panel with Ignition Lock43
Disassembling and Assembling, Installing Display Panel43
Removing and Installing Handlebar Controls44
Testing Operation of Alternator, Regulator and Diode Plate44
Testing Regulator44
Quick Test of Alternator and Regulator44
Removing and Installing Battery45
Removing and Installing Fuse Box45
Removing, Testing and Installing Relays46
Testing Operation of Turn Signal Relay46
Testing Operation of Starter Relay46
Removing and Installing Regulator47
Removing/Installing Ignition Control Unit47
Removing, Testing and Installing Ignition Coil47
Removing, Testing and Installing Diode Plate48
Removing and Installing Ignition Trigger48
Replacing Carbon Brushes48
Removing Testing, Disassembling and Assembling Alternator49
Testing Starter50
Disassembling Stator50
Assembling Stator50
Testing with Voltmeter50
Removing, Disassembling, Assembling and Installing Starter51
Removing and Installing Switch for Idle Display52
Assembling Starter52
Installing Starter52
Removing and Installing Oil Pressure Switch52
Removing and Installing Rear Stop Light Switch53
Removing and Installing Front Stop Light Switch53
Removing and Installing Clutch Switch53
Removing and Installing Horn53
Removing and Installing Chassis Cable Harness Section54
Removing and Installing Rear Cable Harness Section54
Troubleshooting55
Brake System58
Removing Front Wheel Brake60
Removing Brake Caliper60
Removing Front Wheel60
Removing Brake Disc60
Disassembling Brake Caliper GS61
Assembling Brake Caliper GS61
Removing and Installing Front Brake Pads62
Stripping down R 100R Brake Caliper62
Assembling R 100R Brake Caliper63
Removing Brake Line63
Installing Front Wheel Brake65
Installing Brake Claiper65
Removing Rear Wheel Brake66
Installing Brake Line66
Removing Rear Wheel66
Removing Brake Shoes67
Removing Brake Lever67
Installing Rear Wheel Brake68
Installing Foot Brake Lever68
Installing Brake Key and Brake Lever68
Installing Brake Shoes68
Suspension70
Replacing Wheel Bearings73
Installing Wheel Bearings73
Removing Handlebars74
Disassembling and Assembling Grip Units74
Disassembling Left Grip Unit75
Assembling Left Grip Unit75
Removing Telescopic Fork76
Disassembling Telescopic Fork GS77
Removing and Installing Shaft Seal and Sliding Bush in Sliding Tube78
Stripping down Telescopic Fork79
Stripping down the Fixed Tube79
Measuring Telescopic Fork Alignment80
Examining Stanchions80
Examining Bottom Fork Bridge80
Examine Parallelisms of the Stanchions80
Assembling Telescopic Fork GS81
Assembling Telescopic Fork R 100 R81
Assembling Stanchions82
Removing and Installing ST Head Bearing83
Removing and Installing Bottom Taper Roller Bearing83
Examining Front Frame Section84
Installing Telescopic Fork85
Installing Handlebars86
Installing Headlight and Instruments86
Installing Front Wheel87
Measuring Track Alignment87
Removing and Installing Spokes89
Examining Rims for Runout Centering89
Front Wheel Rim89
Rear Wheel Rim89
Static Wheel Balancing90
Centering Lateral Runout90
Removing, Disassembling and Assembling Rear Spring Strut91
Stripping down Input Bevel Pinion93
Removing the Needle Roller Bearing93
Installing the Needle Roller Bearing93
Installing the Input Bevel Pinion94
Assembling the Input Bevel Pinion94
Installing Crown Wheel95
Shimming the Crown Wheel95
Adjusting Tooth Backlash95
Checking Tooth Contact Pattern96
Installing the Housing Cover96
Shimming the Housing Cover96
Removing and Installing Taper Roller Bearings97
Installing Rear Wheel Drive98
Installing Spring Strut98
Frame Attachments99
Installing Rear Wheel99
Removing and Installing Rear Mudguard101
Removing Rear Frame Section101
Removing Rear Mudguard101
Removing and Installing Side Stand, GS102
Removing and Installing Cylinder Guard102
Disassembling Rear Frame Section102
Removing and Installing Kickstand103
Removing, Disassembling and Assembling Installing Foot Rests103
Removing and Installing Air Filter Box104
Installing Foot Rests104
Removing Air Filter Box104
Exhaust System105
Removing and Installing Battery Mount105
Removing and Installing Steering Lock105
Removing and Installing Exhaust System107
Removing Main Silencer107
Removing Main Silencer GS107
Removing Front Silencer and Exhaust Manifold108
Installing Front Silencer and Exhaust Manifold108
Installing Main Silencer GS108
Installing Main Silencer R100R108
Gearbox109
Removing Transmission111
Disassembling Transmission112
Removing and Installing Kick Starter114
Removing Bearing Block for Shift Discs114
Disassembling Bearing Block114
Assembling Bearing Block114
Removing and Disassembling Input Shaft115
Assemlbing Input Shaft115
Removing Output and Intermediate Shafts116
Disassembling Output Shaft117
Assembling Output Shaft117
Replacing Roller Bearing of Input Shaft117
Replacing Radial Seal for Input Shaft117
Assembling Transmission118
Calculating Thickness of Spacer Ring for End Play118
Example of Calculation118
Installing Transmission120
Troubleshooting Transmission121
Disassembling and Assembling Gear Shaft Linkage121
Installing Shift Lever121
Clutch122
Removing and Installing Clutch124
Engine126
Fuel Preparation128
Removing and Disassembling Fuel Tap128
Removing and Installing Bowden Cable for Cold Start Device128
Removing and Installing Bowden Cables for Throttle Control129
Removing Carburetor129
Disassembling Carburetor130
Removing Nozzle Set130
Assembling Carburetor131
Removing Shed Fuel System132
Removing Engine134
Disassembling Engine135
Removing Cylinder Head135
Disassembling Cylinder Head135
Checking Valve Guide for Wear136
Reaming out Valve Guide137
Replacing Valve Guides137
Installing Valves138
Removing Cylinder139
Removing Conrod139
Examining Piston and Cylinder139
Examining and Repairing Conrod140
Examining Conrd for Parallelism and Twisting141
Removing Oil Pump142
Examining Oil Pump142
Assembling Oil Pump142
Replacing Radial Seal for Crank Shaft Seal142
Removing Chain Box Cover143
Installing Seal143
Replacing Radial Seal for Crankshaft Seal144
Removing Camshafts144
Examining Camshaft144
Removing Crank Shaft145
Determining Crankshaft Bearing Play145
Removing Crankshaft Bearing146
Removing Oil Sump and Intake Bell146
Removing and Installing Belt Cover146
Removing and Installing Bypass Valve146
Assembling Engine147
Installing New Crankshaft Bearing Bush in Bearing Cover147
Examining Conrdo Bearing Play148
Installing Crankshaft148
Installing Camshaft149
Attaching Chain Box Cover150
Installing Oil Pump150
Installing Piston150
Installing Cylinder151
Attaching Cylinder Head151
Installing Engine152
Installing Intake Bell and Oil Sump152
Removing and Disassembling Oil Cooler153
Troubleshooting Engine154
Insufficient Compression Pressure154
Poor Performance154
Engine Pings154
Technical Data155
Engine Does Not Accelerate Properly155
Engine Cuts out - High Fuel Consumption155

Brand	BMW Motorrad
Model	R 100 GS
Category	Motorcycle
Language	English

BMW Motorrad R 100 GS User Manual

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BMW Motorrad R 100 GS Specifications

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