BMW R 1100 S Repair Manual
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BMW R 1100 S Repair Manual

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Repair Manual
R 1100 S
BMW AG Motorcycle Division
After Sales

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  • Page 1 Repair Manual R 1100 S BMW AG Motorcycle Division After Sales...
  • Page 2 Published by: © BMW AG Motorcycle Division After Sales UX-VS-2 All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission. Errors and omissions excepted; subject to technical amendment. Produced in Germany 06/99...
  • Page 3 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.
  • Page 5 Contents Group / Chapter 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...
  • Page 6 Group / Chapter 34 Brakes 36 Wheels and tyres 46 Frame 51 Equipment 52 Seat 61 General electrical equipment 62 Instruments 63 Lights...
  • Page 7 Licence plate No. Order No. Mechanic’s signature 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,...
  • Page 8 BMW AG Motorcycle Division Pre-delivery check R 1100 S Customer Licence plate No. Pre-delivery check Order No. Mechanic’s signature Checking the shipping crate for damage Motorcycle: – unpack – attach items supplied loose – inspect for damage – check that delivery is complete:...

  • Page 9: Maintenance And General Instructions

    00 Maintenance and general instructions Tightening torques and Table of consumables Pre-delivery check Maintenance Contents Page Tightening torques ........................5 Table of consumables ......................11 00.1...

  • Page 10: Table Of Contents

    Pre-delivery check 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...
  • Page 11 Maintenance Contents - Maintenance Page Maintenance ..........................20 Key to maintenance intervals ....................20 Reading out MoDiTeC fault memory ................20 (Inspections I, II, III and IV) Changing engine oil, replacing oil filter element ............20 (Inspections I, II, III and IV) Changing oil in gearbox ......................21 (Inspections III and IV) or every 2 years at the latest...
  • Page 12 Contents - Maintenance Page Changing brake fluid and bleeding brake system ...........30 Change the brake fluid annually (Inspection IV) [ABS Inspections II and III] Bleeding front brake circuit/changing brake fluid ............30 Additional information for [ABS] Bleeding rear brake circuit/changing brake fluid ............32 Checking clutch fluid level ....................33...

  • Page 13: Tightening Torques

    Tightening torques Model R 1100 S Connection 11 Engine Cylinder head Tightening sequence: 1. Tighten cylinder head nuts (oiled) in diagonally opposite sequence 1.1 Tighten all nuts to closing torque 1.2 Tighten all nuts to wrench angle 90° 1.3 Tighten all nuts to wrench angle 90°...
  • Page 14 Model R 1100 S Connection 11 Engine Oil pump Mesh filter basket to engine block Oil pump cover Pressure relief valve Oil pressure switch Oil cooler Oil cooler pipe to engine block Cooling oil line – banjo screw with oil vent valve Oil cooler to fairing bracket Oil cooler return line to engine block Oil cooler connection to crankcase...
  • Page 15 Model R 1100 S Connection 12 Engine electrics Starter motor to engine Starter cover to gearbox housing Alternator to cover mount Tensioning and retaining link to alternator Spacer to alternator Belt pulley to alternator Series generator 560 W Do not release Option 700 W Belt pulley to crankshaft Poly-V belt preload...
  • Page 16 Model R 1100 S Connection 23 Transmission Oil drain plug Oil filler plug Gearbox to engine block Foot shift lever to footrest plate Selector lever to selector shaft Gearbox cover to gearbox housing 31 Front fork Quick-release axle clamp screws Clamp, fork fixed tube to fork bridge Slider tube bridge to slider tube 25 (clean thread + Loctite 243)
  • Page 17 Model R 1100 S Connection 33 Rear wheel drive Reaction link to rear wheel drive/main frame Load approx. 85 kg (187 lbs) onto motorcycle and tighten loose reaction link Spring strut to main frame Spring strut to rear swinging arm 34 Brakes Brake caliper to fork slider tube Brake caliper to rear wheel drive...
  • Page 18 Model R 1100 S Connection 46 Frame Main frame to engine M 10 screw, top right Initial tightening 13 Final tightening 42 M 10 screw, top left M 10 bolts at top (struts to engine) M 10 screw, long, frame/gearbox M 12 screw, bottom M 8 screw, long, bottom Rear frame to main frame...
  • Page 19 83 19 9 407 855 500 ml spray housings Crack testing agent for aluminium Developer MR 70 81 22 9 407 495 500 ml spray housings Installation aid BMW cooling spray Cooling spray 83 19 9 407 762 300 ml spray 00.11...
  • Page 20 00.12...

  • Page 21: Pre-Delivery Check

    Pre-delivery check General view of crated motorcycle 00.13...

  • Page 22: Checking The Crate For Damage

    Tel. +49 89 14327 632 Check for defects. • Fax. +49 89 14327 709 Send an “Urgent notification” to • Immediately notify the freight carrier (e.g. freight BMW AG, Sparte Motorrad, UX-VS-1 forwarder). Fax No. +49 89 382 33220 • Rectify the defect. •...

  • Page 23: Filling And Charging The Battery

    S000020 Filling and charging the battery Filling and charging the battery Disengaging and raising the fuel tank Warning: • Remove seat. Battery acid is severely caustic. • Remove right and left side trim panels. Protect your eyes, face, hands and clothing and the paintwork.

  • Page 24: Checking Engine Oil Level When Cold, Adding Oil If Necessary

    • Check the oil level with the motorcycle upright: if necessary, use stand, BMW No. 00 1 560, to Tightening torque: keep the motorcycle in the upright position. Fuel tank to rear frame ......... 10 Nm Caution: Never top up the engine-oil level past the MAX mark.

  • Page 25: Checking Clutch Fluid Level

    • Motorcycle upright; if necessary, use stand, Rear brake BMW No. 00 1 560, to hold the motorcycle up- right. • • Turn the handlebar fully to the right. Motorcycle upright; if necessary, use stand, BMW No.

  • Page 26: Checking Headlight Beam Angle, Adjusting If Necessary

    Checking headlight beam angle, Checking tightness of rear wheel adjusting if necessary studs Tightening torque: Rear wheel studs ........105 Nm Checking tyre pressures • Check/correct tyre pressures. Tyre pressures: Solo ........front 2.2 bar (31.3 psi) ..........rear 2.5 bar (35.6 psi) Two-up ........

  • Page 27: Final Inspection And Function Check

    Final inspection and function check Handing over the motorcycle • Clutch This is the ideal opportunity to familiarise the cus- • Check gear shift action. tomer with the motorcycle in order to ensure the • Handbrake and foot brake customer’s satisfaction and safety. •...

  • Page 28: Maintenance

    Remove oil drain plug and drain off oil. • Fit new seal and screw in drain plug. • Use oil filter wrench, BMW No. 11 4 650, to re- move the oil filter. • Coat sealing ring on new oil filter element with oil and install filter.

  • Page 29: Changing Oil In Gearbox

    S000120 • Remove oil filler plug (1). • Use socket-head key, BMW No. 23 4 690 and torque wrench, to remove oil drain plug (2) and drain the oil into a suitable container. • Clean the magnet in the oil drain plug.

  • Page 30: Changing Oil In Rear Wheel Drive; Cleaning Inductive Signal Transmitter At Rear Wheel

    Changing oil in rear wheel drive; cleaning inductive signal transmitter at rear wheel (Inspections I, III and IV) Every 40 000 km (24 000 miles) or every 2 years at the latest • Change the oil with the rear wheel drive at oper- ating temperature.

  • Page 31: Replacing Fuel Filter

    • Disengage the fuel tank. • Seal the fuel feed and return lines with hose clips, BMW No. 13 3 010, and disconnect. • Pull the plug connector off the fuel pump unit. • Remove the fuel tank.
  • Page 32 Note correct direction of flow through fuel filter. Make sure that breather lines are correctly routed. • Secure non-reusable hose clips with pliers, BMW No. 13 1 500. Caution: Make sure that O-ring (2) is in perfect condition. Tightening torque: Fuel pump unit ..........

  • Page 33: Checking Battery Fluid Level And Topping Up If Necessary; Cleaning And Greasing The Battery Posts

    S000020 Checking battery fluid level and Replacing intake air filter element topping up if necessary; cleaning and (Inspection III) greasing the battery posts In very dirty and dusty operating conditions, replace every 10 000 km (6 000 miles) or even (Inspections III and IV) more frequently if necessary •...

  • Page 34: Replacing Poly-V Belt

    Pull off spark plug caps with special puller, BMW No. 12 3 520. Poly-V belt tensioning procedure: • Use spark plug wrench, BMW No. 12 3 510, to 1. Hand-tighten hex nut (1) on adjusting screw (2) remove the spark plugs. (do no use tools).

  • Page 35: Checking Brake Fluid Level

    Rear brake operation and freedom from leaks; • Motorcycle upright; if necessary, use stand, repairing/replacing if necessary BMW No. 00 1 560, to hold the motorcycle up- (Inspection III) right. • Checking brake system for leaks. Checking brake fluid level...

  • Page 36: Checking Brake Pads And Discs For Wear/Replacing

    Checking brake pads and discs for Checking brake disc wear wear/replacing (Inspections II and III) Checking front brake pad wear S000160 • Examine the brake discs carefully for cracks, damage, distortion, wear and score-marks. S000140 Brake disc wear limit: front:..........4.0 mm (0.16 in) •...

  • Page 37: Replacing Brake Pads, Front Brake

    Installation is the reverse of the removal proce- dure. • Before installing the brake caliper, force the pis- tons fully back with resetting tool, BMW No. 34 1 500. Tightening torque: Brake caliper to fork slider tube....40 Nm 00.29...

  • Page 38: Changing Brake Fluid And Bleeding Brake System

    ....See Additional information for [ABS] 34 1 500 S000190 S000261 • Use resetting tool, BMW No. 34 1 500, to force • the pistons of the right-hand brake caliper fully Wrap a cloth around the filler adapter in the right back.

  • Page 39: Additional Information For [Abs]

    Draw off brake fluid until it emerges clear and • Motorcycle upright; if necessary, use stand, free from air bubbles. • BMW No. 00 1 560, to hold the motorcycle up- Close the bleed screw. right. Tightening torque: Bleed screw in pressure modulator ....9 Nm S000071 •...

  • Page 40: Bleeding Rear Brake Circuit/Changing Brake Fluid

    [ABS] Begin by bleeding the pressure modula- tor. Brake fluid grade .........DOT 4 ....See Additional information for [ABS] • Use the auxiliary stand, BMW No. 00 1 560. Tightening torque: • Remove reservoir cover. Bleed screw in rear brake caliper ....6 Nm Brake caliper to rear wheel drive ....

  • Page 41: Checking Clutch Fluid Level

    If other devices are used, comply with their manu- facturers’ instructions. • Place the motorcycle on the auxiliary stand, BMW No. 00 1 560, and turn the handlebars fully to the right. S000051 • Remove reservoir cover with rubber diaphragm.

  • Page 42: Checking Tightness Of Rear Wheel Studs

    Checking tightness of rear wheel Caution: studs The motorcycle is not permitted on the road without the grubscrew in place and secure in the filler adapt- (Inspection I) • Check security of the rear wheel studs with a • Correct the fluid level. torque wrench.

  • Page 43: Greasing The Side Stand Pivot

    C000060 • • Check free movement of side stand and grease Remove spark plugs with the spark plug wrench, if necessary. BMW No. 12 3 510. • Grease pivot point (arrow). Lubricant: Caution: For side stand pivot..... Shell Retinax EP2 Do not bend electrodes –...

  • Page 44: Tightening Cylinder Heads

    Tightening cylinder heads Checking/adjusting valve clearances (Inspection I) (Inspections I, II and III) C000210 RS110980 • Remove cylinder head cover. • Check valve clearance with feeler gauge and, if Caution: necessary, correct with adjusting screw. Catch escaping oil. Adjust valve clearances with the engine cold (max.

  • Page 45: Checking Throttle-Cable Play

    Checking throttle cable for ease of Play of throttle cable: ..approx. 2 mm (0.08 in) movement, abrasion and kinks; • Connect hose of BMW Synchro to vacuum replacing if necessary adapter and connect cables to BMW MoDiTeC. Checking throttle-cable play •...

  • Page 46: Final Inspection With Road Safety And Functional Check

    Final inspection with road safety and functional check (Inspections I, II, III and IV) Road safety check • Check wheels and tyres. • Check/correct tyre pressures. • Wait at least 10 minutes after the trial run/road test before checking/correcting engine oil level. Tyre pressures: Solo ........
  • Page 47 11 Engine Contents Page Technical Data ..........................5 Cutaway drawing of engine Lubricating-oil circuit .......................11 Cooling-oil circuit ........................13 Removing engine ........................15 Disassembling engine ......................17 Removing cylinder head cover ....................18 Locking the engine at TDC .......................19 Firing TDC ............................19 Removing and installing chain tensioner ............................20 Work instructions, timing-chain tensioner ..................20...
  • Page 48 Contents Page Removing auxiliary shaft drive ....................33 Removing oil pump ........................34 Removing radial shaft seal from crankshaft with engine installed .....................35 Disassembling crankcase ......................36 Removing crankshaft, auxiliary shaft and timing chain tensioning and slide rails ...............38 Removing and installing oil intake strainers ..............39 Replacing oil level sight glass ....................39...
  • Page 49 Contents Page Adjusting valve clearances .......................55 Installing right cylinder head ....................56 Adjustment specification ........................56 Installing left cylinder head .......................57 Adjustment specification ........................57 Installing alternator mount cover ...................59 Installing magnetic gate/belt pulley ..................59 Timing the ignition ..........................60 Installing alternator ........................61 Installing engine ..........................62 11.3...
  • Page 50 11.4...

  • Page 51: Technical Data

    Technical Data R 1100 S Engine, general Engine design Four-stroke flat twin, air-cooled with oil- cooled exhaust ports, installed longitudinal- ly, 4 valves per cylinder, two overhead cam- shafts, electronic fuel injection. Location of engine number Crankcase Cylinder bore mm (in) 99 (3.9) Stroke mm (in) 70.5 (2.78) Effective displacement...
  • Page 52 Technical Data R 1100 S Valves Included valve angle ° 41 Valve clearances with engine cold (max. 35 °C/95 °F) Inlet valve mm (in) 0.15 (0.059) Exhaust valve mm (in) 0.30 (0.012) Valve timing without valve clearance, 3 mm (0.12 in) valve lift Inlet opens 5°...
  • Page 53 Technical Data R 1100 S Valve guide Valve guide Extl. dia. mm (in) 12.533...12.544 (0.4934...0.4939) Bore in cylinder head mm (in) 12.500...12.518 (0.4921...0.4928) Overlap mm (in) 0.015...0.044 (0.0006...0.0017) Repair stages Replacement valve guide Extl. dia. mm (in) 12.550...12.561 (0.4941...0.4945) Oversize valve guide Extl.
  • Page 54 Technical Data R 1100 S Bucket-type tappet Extl. dia. mm (in) 23.947...23.960 (0.9428...0.9433) Bore in cylinder head mm (in) 24.000...24.021 (0.9449...0.9457) Radial clearance mm (in) 0.040...0.074 (0.0016...0.0029) Wear limit mm (in) 0.18 (0.007) Auxiliary shaft Bore in crankcase front/back mm (in) 25.020...25.041 (0.9851...0.9859) Auxiliary shaft dia.
  • Page 55 Technical Data R 1100 S Connecting rod Big-end bore mm (in) 51.000...51.013 (2.0079...2.0084) Big end bearing dia. mm (in) 48.016...48.050 (1.8904...1.8918) Radial clearance mm (in) 0.025...0.075 (0.010...0.0030) Wear limit mm (in) 0.13 (0.005) Width of big end bearing eye mm (in) 21.883...21.935 (0.8616...0.8636) Conrod end float mm (in) 0.130...0.312 (0.0051...0.0123) Wear limit...
  • Page 56 Technical Data R 1100 S Piston rings 1st groove Piston ring asymmetric, convex oval Thickness mm (in) 1.170...1.190 (0.0461...0.0469) Wear limit mm (in) 1.1 (0.04) End gap mm (in) 0.1...0.3 (0.004...0.012) Wear limit mm (in) 0.8 (0.03) Side clearance mm (in) 0.030...0.070 (0.0012...0.0027) Wear limit mm (in) 0.15 (0.006) 2nd groove Micro-taper compression ring...

  • Page 57: Cutaway Drawing Of Engine

    Cutaway drawing of engine 11.11...

  • Page 58: Lubricating-Oil Circuit

    Lubricating-oil circuit 11.12...

  • Page 59: Cooling-Oil Circuit

    Cooling-oil circuit 11.13...
  • Page 60 11.14...

  • Page 61: Removing Engine

    34/Removing ABS unit S110010 • [ABS] Remove the pressure modulator. • • Secure stand, BMW No. 00 1 520, to motorcy- Remove the rear side panel on the right. • cle. Disconnect plug for rear wiring harness. • •...
  • Page 62 • • Use pliers, BMW No. 17 5 500, to release hose Remove front silencer. • clip securing breather hose to air filter box. Use a strap with ratchet latch to secure bottom • Remove air filter box. fork bridge to top fork bridge.

  • Page 63: Disassembling Engine

    00 0 630 RS110010 Disassembling engine • Secure engine mount, BMW No. 11 0 630, to the engine block. • Transfer engine to assembly frame. 11 4 650 RS110950 • Drain engine oil. • Remove the oil filter, using oil filter wrench, BMW No.

  • Page 64: Removing Cylinder Head Cover

    12 3 510 RS110020 Removing cylinder head cover • Remove spark plugs with the spark plug wrench, BMW No. 12 3 510. • Remove cylinder head cover. Caution: Catch escaping oil. 11.18...

  • Page 65: Locking The Engine At Tdc

    Lock the clutch housing with special tool, BMW No. 11 5 640. RS110461 Note: The engine can be locked at TDC by inserting locat- ing pin, BMW No. 11 2 650, through the hole in the clutch housing and the engine block. 11.19...

  • Page 66: Removing And Installing Chain Tensioner

    RS110060 Removing and installing chain tensioner Caution: Do not mix up the chain tensioner pistons. When in- stalling, fit a new seal. Work instructions, timing-chain tensioner Removing: • Remove timing chain tensioner, then remove camshaft sprocket from camshaft. Installing: • First install camshaft sprocket, then timing chain tensioner.

  • Page 67: Removing Valve Gear Holder

    M6 x 60 M6 x 30 M6 x 30 M6 x 30 S110110 Removing valve gear holder • Remove valve gear holder. • Secure rockers with a rubber band (2). Note: If no work is carried out on the valve gear holder, re- move it together with the cylinder head.

  • Page 68: Disassembling/Assembling Valve Gear Holder

    RS110080 Disassembling/assembling valve gear holder • Remove bearing cap. • Insert a suitable pin into the bore (arrow) of the rocker shaft, and turn the shaft back and forth to remove it from its bearing. • Remove pushrods. Caution: Do not mix up the rocker shafts and pushrods. 11.22...
  • Page 69 RS110090 • Remove camshaft bearing cap (1). • Remove camshaft and bearing (2). • Remove bucket-type tappets. Caution: Do not mix up the bucket-type tappets. • Assembly is the reverse of the disassembly pro- cedure. Caution: Note direction of installation (3) for camshaft bearing cap.

  • Page 70: Removing Cylinder Head

    M10 x 70 M6 x 30 M6 x 30 M6 x 30 RS110110 Removing cylinder head 11.24...

  • Page 71: Disassembling, Checking, Repairing And Reassembling Cylinder Head

    Do not scratch sealing face on cylinder head. Place the head on a clean, non-scratching surface. • Mount valve spring compressor, BMW No. 11 5 690, on cylinder head. • Compress the valve springs. • Gently tap valve head to release collets from spring retainer.

  • Page 72: Checking Valves For Wear

    Checking valves for wear • Clean combustion residue from valves. • Check valve dimensions..........see Technical Data Remachining valve seat RS110890 Caution: Width (B) and diameter (D) must always be main- tained if valve seat is machined..........see Technical Data Checking and repairing cylinder head •...

  • Page 73: Replacing Valve Guides

    Immediately before pressing in, the temperature • Drive out valve guides with 5 mm (0.20 in) dia. must be –40 °C (–40 °F). drift, BMW No. 11 5 674, from the combustion • chamber side. Place heated cylinder head flat on workbench or •...

  • Page 74: Installing Valve And Valve Stem Seal

    Shrink a short length of tube (arrow) on to the end of the valve stem. • Install the valve stem seal with a 5 mm (0.20 in) dia. drift, BMW No. 11 5 602. Caution: Remove the shrink-fit tube. •...

  • Page 75: Removing Cylinder

    RS110170 Removing cylinder • Remove guide rail bearing screws (1). • Remove cylinder retaining screws, and remove cylinder. Caution: When removing cylinder, make sure that the piston does not strike the engine block. Removing and disassembling piston • Remove both retaining rings from piston pin. •...

  • Page 76: Checking Pistons And Cylinders

    Checking pistons and cylinders Assembling pistons Reference temperature for measurements: ............20 °C (68 °F) S110170 RS110180 • Carefully fit piston rings to piston in the following • Measure cylinder bore with internal probe at sequence, using piston ring pliers: 20 mm (0.79 in) and 100 mm (3.94 in) from the 3rd groove - 3-S ring top in direction of piston pin, and again at a right...

  • Page 77: Removing And Installing Conrod

    Turn crankshaft to TDC position. • • Lock the clutch housing with special tool, Screw the big end bolts in by hand, then tighten BMW No. 11 5 640. them with a tightening angle indicator, • Remove conrods. BMW No. 11 2 500.

  • Page 78: Removing And Installing Alternator Mount Cover With Engine Installed

    It is not necessary to remove magnetic gate (2) when Drive in the new radial shaft seal with drift and removing the alternator mount cover as a unit. sliding sleeve, BMW No. 11 5 680. • Remove alternator mount cover (3).

  • Page 79: Removing Auxiliary Shaft Drive

    Remove chain tensioning rail (3). • Remove chain guide rail (4). • Lock the clutch housing with special tool, BMW No. 11 5 640. • Remove chain sprocket retaining bolt (5). • Remove sprocket (6) and timing chain (7). •...

  • Page 80: Removing Oil Pump

    M6 x 45 M6 x 50 M6 x 45 M6 x 45 RS110410 M6 x 50 Removing oil pump • Remove oil pump cover (1). • Remove complete oil pump (2) together with cooling oil pipe (3), and disassemble. Caution: Check installed positions of parts which have al- ready been run together.

  • Page 81: Removing Radial Shaft Seal From Crankshaft With Engine Installed

    Using awl, BMW No. 00 8 583, carefully punch a hole in the shaft sealing ring. • Screw the pull rod, BMW No. 00 8 581, into the hole and use impact weight, BMW No. 00 8 582, S110040 to remove the shaft sealing ring.

  • Page 82: Disassembling Crankcase

    RS110261 Disassembling crankcase • Turn engine on to its side. • Remove screws on right side. 11.36...
  • Page 83 RS110260 • Turn engine on to its side. • Remove screws on left side. • Remove upper section of crankcase. 11.37...

  • Page 84: Removing Crankshaft, Auxiliary Shaft And Timing Chain Tensioning And Slide Rails

    S110050 Removing crankshaft, auxiliary shaft and timing chain tensioning and slide rails 11.38...

  • Page 85: Removing And Installing Oil Intake Strainers

    • Coat the sealing face of the new oil level sight glass with engine oil and drive it in with drift, BMW No. 00 5 550. Removing and installing oil thermostat S110070 •...

  • Page 86: Measuring Crankshaft Bearing Play

    RS110310 Measuring crankshaft bearing play Measuring radial bearing play • Measure main bearing journal with an external micrometer in two planes, A and B, at right an- gles. • Enter measured values on record sheet..........See Technical Data Caution: The crankshaft can only be reground in grinding stage 0;...

  • Page 87: Installing Main Bearings

    00 2 510 RS110910 • Screw measuring device, BMW No. 00 2 500, with dial gauge, BMW No. 00 2 510, into tapped hole for alternator carrier cover. • Move crankshaft forwards and backwards and read axial play from dial gauge.

  • Page 88: Measuring Big End Bearing Play

    ........... See Technical Data • Install bearing shells and assemble conrods. • Using tightening angle indicator, BMW No. 11 2 210, tighten the big end bolts. Tightening torque: Big end bolts oiled Joint torque..........20 Nm Wrench angle ............ 80°...

  • Page 89: Assembling Engine

    Clamp crankshaft in a vise with protective jaws. • Oil the big end bolts, screw them in by hand and tighten with tightening angle indicator, BMW No. 11 2 500. Caution: Oil the bearings. Make sure that conrods and bearing shells are re- installed in their original positions.

  • Page 90: Installing Crankshaft

    S110080 Installing crankshaft Installing auxiliary shaft/timing chains • When installing the auxiliary shaft, make sure that Caution: the bore in the auxiliary shaft (2) facing the crank- Oil the bearings. shaft is in line with the crankcase mating face. Caution: Installing timing chain tensioning and Timing chains (3) must mesh fully with auxiliary shaft sprockets.

  • Page 91: Assembling Engine Block

    RS110920 Assembling engine block • Clean and degrease sealing faces (arrow) and coat with 3-Bond 1209. • Secure the timing chain with rubber band (1) to the timing chain tensioner and slide rail. 11.45...
  • Page 92 RS110391 • Bolt the crankcase sections together. Tightening torque/tightening order: 1. M 10 screw (oiled) Initial torque ..25 Nm Wrench angle ..... 90° 2. M 8 screw (oiled) ........22 Nm 3. M 6 screw ..........9 Nm 11.46...
  • Page 93 11 5 702 11 5 703 11 5 703 11 5 703 11 5 702 11 5 703 11 5 703 11 5 701 00 5 500 00 5 500 11 5 661 11 5 661 11 5 662 11 5 662 00 5 500 11 5 661 11.47...

  • Page 94: Installing Radial Shaft Seals On Crankshaft

    Remove assembly sleeve (3). • Mount sleeve complete with radial shaft seal on crankshaft (4). • Use drift, BMW No. 11 5 701, together with the sleeve (5) to drive the radial shaft seal onto the crankshaft. • Remove sleeve (6).

  • Page 95: Installing Clutch Housing

    • Install clutch housing with mark (1) aligned with crankshaft mark (2). • Lock the clutch housing with special tool, BMW No. 11 5 640. • Insert all screws by hand and tighten down. Tightening torque: Clutch housing to crankshaft (screw threads oiled) ........

  • Page 96: Installing Oil Pump

    M6 x 45 M6 x 50 M6 x 45 M6 x 45 M6 x 50 RS110411 Installing oil pump Caution: Oil the friction faces. • Install outer rotor (1) of oil pump in pump hous- ing. • Install oil pump housing with cooling oil pipe (2). Caution: O-ring (3) must be in perfect condition.

  • Page 97: Installing Auxiliary Shaft Drive

    M 6 screw ............ 10 Nm Banjo bolt for cooling oil line with oil vent valve ......... 25 Nm • Lock the clutch housing with special tool, BMW No. 11 5 640. • Install chain sprocket (1). Tightening torque: M 6 screw ............ 10 Nm •...

  • Page 98: Installing Piston

    RS110430 Installing piston • Turn oil scraper ring so that gap (arrow) is at top. • Install piston rings with gaps offset by 120°. Production locating point X = install on exhaust side. Caution: Make sure that retaining rings are properly seated on piston pin.

  • Page 99: Installing Cylinder

    • Oil the cylinder wall. • Compress the piston rings with a clamping strap, BMW No. 11 2 900. • Install the cylinder and at the same time pass the timing chain and the tensioner and guide rails through the timing case cavity.

  • Page 100: Installing Cylinder Head

    • Install cylinder head gasket. Lock the clutch housing with special tool, • Fit cylinder head and insert correctly positioned BMW No. 11 5 640. • camshaft chain sprocket (1) and timing chain into Tighten camshaft chain sprocket. chain cavity.

  • Page 101: Adjusting Valve Clearances

    RS110980 Adjusting valve clearances • Set piston to firing TDC. • Measure valve clearance with feeler gauge. • Correct valve clearance with adjusting screw and tighten locknut. Valve clearances with engine cold (max. 35 °C/95 °F): Inlet ........... 0.15 mm (0.006 in) Exhaust ........

  • Page 102: Installing Right Cylinder Head

    Note: With engine installed, set engine to TDC with dial gauge holder, BMW No. 00 2 650, and dial gauge, BMW No. 00 2 510. Right cylinder = at firing TDC: Locating pin (arrow) on right camshaft sprocket points downwards.

  • Page 103: Installing Left Cylinder Head

    Note: With engine installed, set engine to TDC with dial gauge holder, BMW No. 00 2 650, and dial gauge, BMW No. 00 2 510. Left cylinder = at firing TDC: Locating pin (arrow) on left camshaft sprocket points upwards.
  • Page 104 RS110050 RS110940 • • Install the end cover with O-ring in perfect condi- Install cylinder head cover. tion. Caution: Tightening torque: Make sure that gaskets are correctly seated. Gas- M 6 screw ............9 Nm kets and sealing faces must be free from oil and grease.

  • Page 105: Installing Alternator Mount Cover

    11 5 640 11 5 680 S110090 Installing alternator mount cover • Place assembly sleeve, BMW No. 11 5 680, on crankshaft. • Clean and de-grease sealing face (arrow) and apply 3-Bond 1209. • Install alternator mount cover. Tightening torque: M 8 screw ............

  • Page 106: Timing The Ignition

    11 2 650 RS110461 Timing the ignition • Using TDC locating pin, BMW No. 11 2 650, lock the clutch housing. • Connect BMW MoDiTeC with adapter cable to Hall-effect gate plate. • Set the timing, following the tester instructions.

  • Page 107: Installing Alternator

    RS110480 Installing alternator • Install alternator. Poly-V belt adjusting procedure: Poly-V belt installation procedure: • Hand-tighten hex nut (1) on adjusting screw (2) (do not use tools). • Tighten adjusting screw (2) with a torque wrench and keep preload applied. Tighten upper retain- ing nut (3), then remove torque wrench from ad- justing screw.

  • Page 108: Installing Engine

    Tightening torque: Oil filter (sealing face lightly oiled) ....11 Nm Oil drain plug..........32 Nm 12 3 510 RS000010 • Install spark plugs with spark plug socket wrench, BMW No. 12 3 510. Tightening torque: Spark plug............ 20 Nm 11.62...
  • Page 109 12 Engine electrics Contents Page Technical Data ..........................3 Removing and installing coil and ignition leads ............5 Checking ignition coil resistance .....................5 Removing and installing alternator ..................6 Poly-V belt adjusting procedure: ......................6 Disassembling/assembling alternator ................7 Checking alternator ........................7 Checking armature for short to ground (earth) ..............7 Disassembling/assembling alternator...
  • Page 110 12.2...

  • Page 111: Technical Data

    Technical Data R 1100 S Starter motor Type Permanent-magnet motor with planetary gear drive Gear ratio Planetary gears 5.5 : 1 Power rating kW 1.1 Alternator Type Three-phase alternating-current generator with integrated all-electronic voltage regulator Standard: Denso Option: Bosch Drive Poly-V belt Gear ratio 1 : 1.5...
  • Page 112 12.4...

  • Page 113: Removing And Installing Coil And Ignition Leads

    Remove fuel tank. Caution: Switch off ignition. Disconnect ground (earth) cable from battery and insulate it. • Pull off spark plug cap with special puller, BMW No. 12 3 520. • Remove ignition leads. • Remove the ignition coil. •...

  • Page 114: Removing And Installing Alternator

    RS110480 Removing and installing alternator Note: Disconnecting the battery deletes all entries (e.g. faults, settings) stored in the Motronic control unit’s • Remove seat. memory. • Remove side trim. Loss of settings can temporarily impair the operat- • Remove fuel tank. ing characteristics when the engine is restarted.

  • Page 115: Disassembling/Assembling Alternator

    Remove voltage regulator (4). • Installation is the reverse of the removal proce- dure. Note: The belt pulley cannot be removed. Checking alternator • Test with BMW MoDiTeC. Checking armature for short to ground (earth) • Test with BMW MoDiTeC. 12.7...

  • Page 116: Alternator

    RS120050 Disassembling/assembling Checking alternator alternator • Test with BMW MoDiTeC. (Option 50 A) Checking armature for short to ground (earth) • Remove the cover retaining screws (1). • Release clips (2) and remove the cover. • • Remove voltage regulator (3).

  • Page 117: Removing And Installing Starter Motor

    S120030 Removing and installing starter motor Caution: Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. • Remove screw (1) securing starter motor cover. • Remove the cover. • Disconnect leads (2). • Remove screws (3) securing starter motor. •...

  • Page 118: Disassembling/Assembling Starter Motor

    RS120080 Disassembling/assembling starter Checking starter motor motor • Test with BMW MoDiTeC. • Disconnect lead (1). Checking starter relay • Remove securing screws (2). • • Remove flange (3). Test with BMW MoDiTeC. • Remove solenoid switch (4) after taking out the retaining screws (5).

  • Page 119: Removing And Installing Magnetic Gate

    • Remove the starter motor. Loss of settings can temporarily impair the operat- • Install locking device, BMW No. 11 5 640, to lock ing characteristics when the engine is restarted. the clutch housing. • Remove Poly-V belt pulley (3) with rotor gate from crankshaft.

  • Page 120: Timing The Ignition

    00 2 510 S120050 • Screw dial gauge holder, BMW No. 00 2 650, and dial gauge, BMW No. 00 2 510, into right or left spark plug bore. • Turn the engine over until the piston is at TDC.

  • Page 121: Fuel Preparation And Control

    13 Fuel preparation and control Contents Page Technical Data ..........................3 Removing and installing air filter housing ..............5 Removing and installing throttle-valve stub pipe ............6 Removing and installing throttle-valve potentiometer ....................7 Removing and installing Motronic control unit ............7 13.1...
  • Page 122 13.2...

  • Page 123: Technical Data

    Technical Data R 1100 S Fuel grade Super (premium), unleaded, 95 octane (RON) Mixture preparation Motronic MA 2.4 Throttle stub pipe intl. dia. mm (in) 45 (1.8) Throttle angle in rest position 5° Air filter Flat-pattern paper element 13.3...
  • Page 124 13.4...

  • Page 125: Removing And Installing Air Filter Housing

    S130010 Removing and installing air filter housing Preparatory work ..........See Group 23 (removal of transmission) 13.5...

  • Page 126: Removing And Installing Throttle-Valve Stub Pipe

    S130020 Removing and installing throttle- Caution: valve stub pipe Make sure that O-ring (5) on throttle-valve stub is in perfect condition. Press in spring keeper of multi-pin plug for throt- • tle-valve potentiometer (1) and disconnect plug. Disengage throttle cables (6) from right and left •...

  • Page 127: Removing And Installing Throttle-Valve Potentiometer

    (basic setting is necessary — see Motronic diagnosis instructions). Remove the throttle-valve potentiometer. • Adjust throttle-valve potentiometer with • BMW MoDiTeC after installing. Mark screws with a paint spot. • S130030 Disconnect plug from Hall sensor. •...
  • Page 128 13.8...
  • Page 129 16 Fuel tank and lines Contents Page Technical Data ..........................3 Removing and installing fuel tank ..................5 Removing and installing fuel filter, fuel pump and fuel level sensor ....6 Removing and installing fuel filter ....................6 Removing and installing fuel pump and fuel level sensor ..........7 Checking fuel pump pressure ......................7 Removing and installing fuel...
  • Page 130 16.2...

  • Page 131: Technical Data

    Technical Data R 1100 S Fuel tank Tank capacity l (Imp. gal/ US gal) 18 (4.0/4.8) including reserve of (Imp. pints/ US quarts) approx. 5 (8.80/5.28) Fuel pump Type Gear-type Make Operating voltage V 12 Fuel pressure bar (psi) 3±0.2 (42.69±2.85) Delivery rate (Imp.
  • Page 132 16.4...

  • Page 133: Removing And Installing Fuel Tank

    • Disconnect the breather and overflow hose at the connector. • Seal the fuel feed and return lines with hose clips, BMW No. 13 3 010, and disconnect. • Remove screws securing fuel tank. • Lift tank at rear. •...

  • Page 134: Removing And Installing Fuel Filter, Fuel Pump And Fuel Level Sensor

    Fuel is flammable and a hazard to health. • Observe relevant safety regulations. Remove and install fuel filter. • Secure non-reusable hose clips with pliers, • Drain fuel tank. BMW No. 13 1 500. • Remove fuel pump unit (1) and disconnect hoses (2). 16.6...

  • Page 135: Removing And Installing Fuel Pump And Fuel Level Sensor

    Motronic control unit C160030 can register the throttle-valve positions. • Connect pressure gauge, BMW No. 16 1 500, to Note: delivery side: use cable clips to secure if neces- Disconnecting the battery deletes all entries (e.g.
  • Page 136 16.8...

  • Page 137: Exhaust System

    18 Exhaust system Contents Page Removing and installing exhaust system ................3 Removing and installing silencer (muffler) ..............................3 Removing and installing exhaust manifolds ............................3 18.1...
  • Page 138 18.2...
  • Page 139 11 7 020 S180010 Removing and installing exhaust • Secure the oxygen sensor with special socket wrench insert, BMW No. 11 7 020. system Removing and installing silencer (muffler) Caution: After a trial run, read out Motronic fault memory. •...
  • Page 140 18.4...
  • Page 141 21 Clutch Contents Page Technical Data ..........................3 Removing and installing clutch ....................5 Removing clutch ..........................5 Installing clutch ..........................5 Removing and installing clutch hydraulic line .............6 Removing and installing clutch slave cylinder .............6 Filling/bleeding clutch line ......................7 21.1...
  • Page 142 21.2...

  • Page 143: Technical Data

    Technical Data R 1100 S Type of clutch Single dry plate with increased-leverage dia- phragm spring Operation Hydraulic, with master and slave cylinders Master cylinder piston dia. mm (in) 13 (0.5) Slave cylinder piston dia. mm (in) 24 (0.9) Clutch fluid DOT 4 brake fluid Clutch plate dia.
  • Page 144 21.4...

  • Page 145: Removing And Installing Clutch

    • Install clutch housing with crankshaft pin (2) lo- ..........Optimoly MP3 paste cated in bore (1). • Install locking device, BMW No. 11 5 640, to lock Tightening torque: clutch housing. Housing cover to flywheel ......12 Nm Caution: Always use new screws for housing and cover.

  • Page 146: Removing And Installing Clutch Hydraulic Line

    Removing and installing clutch Removing and installing clutch hydraulic line slave cylinder • • Remove fuel tank. Secure stand, BMW No. 00 1 520, to motorcy- • Remove the rear brake caliper. cle. • • Remove rear wheel. Remove the rear brake caliper.

  • Page 147: Filling/Bleeding Clutch Line

    Bleed the system again if this happens. • Place the motorcycle on stand, • BMW No. 00 1 560, and turn the handlebars fully Remove the bleed screw. • to the right. Disconnect the brake bleeding device from the •...
  • Page 148 21.8...
  • Page 149 23 Gearbox Contents Page Technical Data ..........................3 Removing and installing gear-shift lever .................5 Removing gearbox ........................5 Replacing the shaft sealing rings in the gearbox housing and gearbox cover ...7 Replacing input shaft sealing ring at input end ..................7 Replacing output shaft sealing ring .....................7 Replacing input shaft sealing ring at output end ..................8 Replacing shaft sealing ring for selector drum ..................8 Replacing sealing ring for selector shaft ....................8...
  • Page 150 23.2...

  • Page 151: Technical Data

    Technical Data R 1100 S Type of gearbox 6-speed gearbox with claw-action shift and inte- gral reaction damper for all gears Gear shift type Pedal-operated lever and selector drum with overshoot detent Gear ratios 1st gear 3.863 2nd gear 3.022 3rd gear 2.393 4th gear...
  • Page 152 23.4...

  • Page 153: Removing And Installing Gear-Shift Lever

    Removing gearbox [ABS] Disconnect brake lines from pressure modulator. 00 1 520 S110010 S340071 • Secure stand, BMW No. 00 1 520, to motorcy- • cle. [ABS] Remove cover and disconnect cables. • Remove seat. • Remove left side trim.
  • Page 154 Release hose clips at the air intake necks. • Push the air intake necks into the air filter box. • Use pliers, BMW No. 17 5 500, to release hose clip securing breather hose to air filter box. • Remove air filter box.

  • Page 155: Replacing The Shaft Sealing Rings In The Gearbox Housing And Gearbox Cover

    • sealing rings. Install the sealing ring with the sealing lip facing inwards, using assembly sleeve, BMW No. 23 4 732, and drift, Replacing input shaft sealing ring at input end BMW No. 23 4 731. • Lever out the shaft sealing ring with a screwdriv- •...

  • Page 156: Replacing Input Shaft Sealing Ring At Output End

    Pierce the shaft sealing ring with awl, BMW No. 00 8 583. • Screw the pull rod, BMW No. 00 8 581, into the pierced hole and use impact weight, BMW No. 00 8 582, to remove the shaft sealing ring.

  • Page 157: Disassembling Gearbox

    S230020 Disassembling gearbox 80…100 Removing gearbox housing • Remove oil filler/level check screw (2). • Remove oil drain plug (7) and drain the oil from the gearbox into a suitable tray. • Remove breather (1). • Unclip cable (3) for neutral indicating switch (4). •...

  • Page 158: Removing Selector Drum

    S230040 Removing selector drum Disassembling/assembling selector shaft • Pull the selector shafts (1) out of the selector forks. • Swing the selector forks (3/8) out towards the edge of the cover (arrows). • Remove locking pin (9). • Press guide plate (5) in the opposite direction to the spring loading (arrow).

  • Page 159: Removing Gearbox Shafts

    If the grooved ball bearings are replaced, the fully- compressed length must be re-adjusted. • Pull off the grooved ball bearings with a universal puller, BMW No. 00 7 500. • Press the output-side grooved ball bearing on to the intermediate shaft.

  • Page 160: Disassembling/Assembling Input Shaft

    (3), thrust block (2) and constant- speed gear (1). • Clamp input shaft (10) other way round in vise. • Use universal puller, BMW No. 00 7 500, and 00 7 500 pressure head (arrow) to pull off grooved ball bearing (11). KR230090 •...

  • Page 161: Assembling Input Shaft

    KR230081 Assembling input shaft • Lightly oil the bearing surface for constant-speed gear (1) on input shaft (10), and install the con- stant-speed gear. • Lightly oil the splines in thrust block (2) and install • Place anti-rattle disc (3) on thrust block (2). •...

  • Page 162: Disassembling/Assembling Output Shaft

    Turn output shaft (6) other way round and clamp into the vise with soft jaws. • Using universal puller, BMW No. 00 7 500, pull off deep-groove ball bearing (1) together with shift gearwheel for 2nd gear (4). 00 7 500 •...

  • Page 163: Assembling Output Shaft

    1st gear 4th gear 3rd gear 2nd gear 5th gear 6th gear KR230120 • Assembling output shaft Install needle roller bearing (14). Caution: Note: To avoid damaging the needle roller bearing on the Assembly starts at the shift gearwheel for 4th gear. splines, spread it carefully at the end face when in- Before assembly, oil all running surfaces lightly with stalling.

  • Page 164: Checking Endplay

    Reverse position of output shaft (6) in vise. • Install sliding gearwheel for 6th gear (17) with the • recess for the selector fork facing the 2nd gear Secure dial gauge, BMW No. 00 2 510, to dial shift wheel (3). gauge stand. • •...

  • Page 165: Checking/Adjusting Fully Assembled Length Of Gearbox Shafts And Selector

    • mounting hole of measuring stand, Place a spacing washer (1) of the correct thick- BMW No. 23 4 761, and set to 0.2 mm (0.008 in) ness on the intermediate shaft and press on the preload. grooved ball bearing.

  • Page 166: Checking/Adjusting Fully Assembled Length Of Output Shaft

    Secure dial gauge, BMW No. 23 4 762, in rear ceeded. mounting hole of measuring stand, • BMW No. 23 4 761, and set to 0.2 mm (0.008 in) Take off spacing washer, grooved ball bearing preload. and reference washer.

  • Page 167: Checking/Adjusting Fully Assembled Length Of Input Shaft

    Secure dial gauge, BMW No. 23 4 762, in front ceeded. mounting hole of measuring stand, • BMW No. 23 4 761, and set to 0.2 mm (0.008 in) Take the input shaft out of the measuring fixture. • preload.

  • Page 168: Checking/Adjusting Fully Assembled Length Of Selector Drum

    KR230190 Checking/adjusting fully assembled length of selector drum • Place spacing washer and both thrust washers on the selector drum. • Using slide gauge, determine fully assembled length “A”. • If necessary, adjust fully assembled length “A” with a shim washer (arrow). Fully assembled length: Selector drum ..

  • Page 169: Shimming Selector Shaft

    Shimming selector shaft Caution: If the housing or the complete selector shaft is re- placed, the selector shaft must be measured and shimmed. KR230220 • Measure dimension “C” from the shoulder on the selector shaft to the back of the sleeve. •...

  • Page 170: Assembling Gearbox

    Installing input, output and • Push assembly sleeve, BMW No. 23 4 712, on intermediate shafts to the input shaft splines. Note: This is necessary only if the shaft sealing ring is in- stalled.

  • Page 171: Installing Selector Shaft

    S230040 Installing selector shaft Installing selector drum • Place a spacing washer of the correct thickness and the input-side thrust washer on selector drum (6) and secure with a small amount of grease. • Swing locking lever (8) toward the drive shaft and install the selector drum.

  • Page 172: Installing Gearbox Housing

    • Apply Loctite 574 sealing compound to the mat- ing face of the cover. • Place assembly sleeve, BMW No. 23 4 732, on the output shaft. C230020 • Place assembly sleeve, BMW No. 23 4 712, on the input shaft.
  • Page 173 S230020 • Insert screws (8) and tighten in diagonally oppo- site sequence. • Install neutral indicator (4) and clip wire (3) into position. • Install breather (1). Caution: Clean metal particles off the magnet in drain plug (7). • Install oil drain plug (7). •...
  • Page 174 23.26...
  • Page 175 31 Front fork Contents Page Technical Data ..........................3 Removing and installing telescopic fork .................5 Removing and installing telescopic fork ................5 Removing and installing ball joint in slider tube bridge ................6 Removing and installing ball joint in fork bridge ...................6 Disassembling/assembling telescopic fork ..............7 Disassembling telescopic fork ....................7...
  • Page 176 31.2...

  • Page 177: Technical Data

    Technical Data R 1100 S Front suspension Type BMW Telelever with external suspension strut Telescopic fork Front wheel caster in normal-load position mm (in) 100 (3.9) Steering lock angle ° 2 x 31 Total suspension travel mm (in) 110 (4.3)
  • Page 178 31.4...

  • Page 179: Removing And Installing Telescopic Fork

    Remove ignition/steering lock. fork ............Group 51 • Installation is the reverse of the removal proce- • Secure stand, BMW No. 00 1 520, to motor- dure. • cycle. Tighten the ball joint with the socket and hex • Remove front wheel.

  • Page 180: Removing And Installing Ball Joint In Slider Tube Bridge

    • Mount the slider tube bridge in retaining fixture, BMW No. 31 5 670/672. • Use w/f 46 socket, BMW No. 31 5 630, to re- lease and tighten ball joint. Tightening torque: Ball joint to slider tube bridge (apply Never Seez to thread) ...... 230 Nm...

  • Page 181: Disassembling/Assembling Telescopic Fork

    • Oil the shaft seal slightly and push it on as far as possible (to stop on slider tube) by striking it lightly with drift, BMW No. 31 5 610, and reduc- ing adapter, BMW No. 31 5 613. •...

  • Page 182: Measuring Telescopic Fork

    Measuring telescopic fork Caution: After an accident, always examine the telescopic fork for cracks and signs of damage. Examining slider tube bridge and fork bridge • Check slider tube bridge and fork bridge for sur- face irregularities. Caution: Replace slider tube bridge/fork bridge if deformed. Checking runout of fixed tube RS310060 •...

  • Page 183: Removing And Installing Leading Link

    • Tighten the ball joint at the leading link with the socket wrench insert and internal hexagon, BMW No. 31 5 600. Tightening torque: Leading link to engine on right ....73 Nm Left screw cap (coat thread lightly with Never Seez) .... 42 Nm...

  • Page 184: Removing And Installing Front Suspension Strut

    Removing and installing front suspension strut • Disengage and pull back the fuel tank. • Remove the horn. • Turn the knob for adjusting suspension-strut damping all the way counter-clockwise = SOFT direction. • Remove the knob for adjusting suspension-strut damping.
  • Page 185 32 Steering Contents Page Technical Data ..........................3 Removing and installing left handlebar fitting ..........................5 Removing and installing right handlebar fitting ..........................6 Removing and installing handlebar ..................7 Removing and installing Bowden-cable divider, Bowden cable for throttle actuation and starting-speed increase ................8 Disassembling Bowden-cable divider ................9 32.1...
  • Page 186 32.2...
  • Page 187 Technical Data R 1100 S Steering lock angle ° 2 x 31 Steering tube diameter mm (in) 22 (0.9) Width across mirrors mm (in) 880 (34.6) 32.3...
  • Page 188 32.4...
  • Page 189 S320010 Removing and installing left handlebar fitting • Remove securing screw (1) and remove handle- bar weight. • Remove securing screws (2) of handlebar grip and remove grip. • Detach lower section (3) of handlebar fitting. • Pull off clutch switch (4). •...
  • Page 190 S320020 Removing and installing right handlebar fitting • Remove securing screw (1) and remove handle- bar weight. • Remove throttle twistgrip cover (2). • Back off the adjuster screw for the throttle cable and disengage the Bowden cable. • Pull off the throttle twistgrip. •...
  • Page 191 S320030 Removing and installing handlebar • Remove left and right handlebar fittings. • Release clamp securing fixed tube to upper fork bridge. • Release clamp securing handlebar. • Remove screws securing handlebars to fork bridge. • Remove retaining ring (1) from upper fork bridge. •...
  • Page 192 S320040 Removing and installing Bowden- cable divider, Bowden cable for throttle actuation and starting- speed increase • Disengage fuel tank and pull to the rear. • Remove Bowden-cable cover from fitting for starting-speed increase and disengage Bowden cable (A). • Remove Bowden-cable cover from fitting for throttle actuation and disengage Bowden cable (B).
  • Page 193 Disassembling Bowden-cable divider S320050 • Remove retainers securing Bowden cables. • Remove Bowden cable for starting-speed in- crease. • Remove retainer (1) for roller of Bowden-cable divider. • Remove Bowden cables. • Installation is the reverse of the removal proce- dure.
  • Page 194 32.10...
  • Page 195 33 Rear wheel drive Contents Page Technical data ..........................3 Removing, disassembling, reassembling and installing rear wheel drive ..5 Removing rear wheel drive ......................5 Removing input bevel pinion .....................5 Disassembling input bevel pinion ....................7 Removing needle roller bearing for input bevel pinion .................7 Installing needle roller bearing for input bevel pinion ................7 Assembling input bevel pinion ....................8...
  • Page 196 33.2...

  • Page 197: Technical Data

    Technical data R 1100 S Rear wheel drive Gear tooth pattern Klingelnberg-Palloid spiral bevel Gear ratio 2.75 : 1 Number of teeth 33 : 12 Backlash mm (in) 0.07...0.16 (0.0027...0.0063) Taper roller bearing preload mm (in) 0.05...0.1 (0.0020...0.0039) Oil grades Brand-name hypoid gear oil, SAE 90 GL 5 Capacity Initial filling/oil changes...
  • Page 198 33.4...

  • Page 199: Removing, Disassembling, Reassembling And Installing Rear Wheel Drive

    Removing rear wheel drive • Raise the motorcycle with the auxiliary stand, BMW No. 00 1 560. • Drain the oil. • Remove the brake caliper and secure it to the rear frame with a cable strap.
  • Page 200 33 1 510 33 1 700 S330030 • Bolt the rear wheel drive to the retaining fixture, BMW No. 33 1 510/511. • Bolt the locking arm (1) to the retaining fixture. • Screw threaded bushings (2) down on to the rear wheel drive and secure them with the wheel studs.

  • Page 201: Disassembling Input Bevel Pinion

    BMW No. 00 8 573, and threaded spindle extension, BMW No. 00 8 575. • Using puller, BMW No. 00 7 500, pull off both bearings at the same time. Installing needle roller bearing for input bevel •...

  • Page 202: Assembling Input Bevel Pinion

    KR330131 C?????? Assembling input bevel pinion • Heat the inner race (1) to 100 °C (212 °F) and push onto input bevel pinion (2) as far as the stop. • Push the outer race (3) together with the roller cage (4) on to the inner race. •...

  • Page 203: Installing Input Bevel Pinion

    33 1 760 • Tighten hex nut (8) with w/f 36 socket wrench in- sert and reduction adapter, BMW No. 33 1 720. Caution: Make sure that the nut does not damage the shaft sealing ring.

  • Page 204: Removing And Disassembling Crown Wheel

    33 1 830 33 1 307 KR330180 • Clamp crown wheel in vise with protective jaws. • Insert thrust block (arrow), BMW No. 33 1 307. • Use puller, BMW No. 33 1 830, to pull off the grooved ball bearing. 33.10...

  • Page 205: Assembling/Installing Crown Wheel

    Assembling/installing crown wheel 00 5 500 00 7 500 23 4 670 KR330190 • Using puller, BMW No. 00 7 500, pull taper roller S330090 bearing off crown wheel. • Heat the housing to 80 °C (176 °F). • Insert the outer race in the bearing seat with drift, BMW No.

  • Page 206: Checking/Adjusting Backlash

    Backlash: housing with the knurled screw. (adjust without oil) • Secure measuring arm, BMW No. 33 2 604, cen- ....... 0.07...0.16 mm (0.0027...0.0063 in) trally to crown wheel. S3300120 • Using the balls of your hands, press the crown wheel into the housing and turn it to and fro to check tooth backlash.

  • Page 207: Checking Tooth Contact Pattern

    Clean and degrease tooth flanks of crown wheel and bevel gear and coat with marking ink. • Install measuring fixture, BMW No. 33 2 600, centre crown wheel and use the balls of your hands to press it into the housing and turn it back and forth a few times.

  • Page 208: Shimming Housing Cover

    Using depth gauge, BMW No. 00 2 550, meas- Using drift, BMW No. 33 1 860, and handle, ure distance a. BMW No. 00 5 500, drive in the sealing ring. • Heat housing cover to 80 °C (176 °F) and install.

  • Page 209: Removing And Installing Rear Swinging Arm

    S330160 • Remove the swinging arm fixed bearing stud bolt. • Using pull rod, BMW No. 00 8 581, and impact weight, BMW No. 00 8 582, pull out the swinging arm fixed bearing stud bolt. • Remove the swinging arm bearing stud bolt.

  • Page 210: Removing And Installing Taper Roller Bearing

    To install the bearing, heat the swinging arm to 80 °C (176 °F). Checking universal joint for wear • Drive in bearing with drift, BMW No. 33 5 700. Removing and installing flexible gaiter KR330360 • Measure axial and radial play.

  • Page 211: Installing Rear Swinging Arm

    S330010 Installing rear swinging arm • Slide swinging arm over drive shaft as far as pos- sible until rubber gaiter connects on housing neck. • Install fixed bearing stud bolt (1). • Install floating-bearing stud bolt (2) with Loctite. • Tighten fixed bearing stud bolt.

  • Page 212: Installing Rear Wheel Drive

    S330011 Installing rear wheel drive • Coat splines of sliding element (arrow) with Tightening torques: Staburags NBU 30 PTM. Fixed bearing stud bolt • Apply grease to inner race of left needle roller (thread cleaned + Loctite 2701)....160 Nm bearing and install.

  • Page 213: Removing And Installing Suspension Strut

    Removing and installing suspension strut Tightening torques: Floating-bearing stud bolt (clean thread + Loctite 2701)......7 Nm Note: Locknut ............160 Nm To remove the suspension strut, support the rear axle. • Load approx. 85 kg (187 lbs) onto motorcycle and tighten loose reaction link (3).
  • Page 214 33.20...
  • Page 215 34 Brakes Contents Page Technical Data ..........................3 Removing and installing front brake caliper ..............5 Disassembling and assembling front brake caliper ..........6 Disassembling front brake caliper ...................6 Assembling front brake caliper ....................6 Removing and installing rear brake caliper ..............7 Disassembling and assembling rear brake caliper ...........8 Disassembling rear brake caliper ....................8...
  • Page 216 Contents Page Removing and installing ABS relay and relay socket ..........19 Removing ABS relay ........................19 Installing the ABS relay ......................19 Removing ABS relay socket ....................20 Installing the ABS relay base ....................20 Removing and installing brake line ..................21 Removing and installing front brake line ................21 Removing and installing rear brake line ................22...

  • Page 217: Technical Data

    Technical Data R 1100 S Brake fluid DOT 4 Minimum lining thickness, front mm (in) 1.0 (0.04) Minimum lining thickness, rear If the brake disc is visible through the bore in the wheel-side brake pad, the brake lining is worn to its minimum permissible thickness.
  • Page 218 34.4...

  • Page 219: Removing And Installing Front Brake Caliper

    Removing and installing front brake Tightening torque: caliper Brake caliper to fork slider tube....40 Nm Brake hose to brake caliper ......18 Nm Bleed screw to brake caliper ....... 14 Nm RS340021 • Drain the brake system. • Disconnect brake line (1). Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid...

  • Page 220: Disassembling And Assembling Front Brake Caliper

    Remove the brake caliper. Using piston compressor (5), • Remove keeper from retaining pin (1). BMW No. 34 1 500, if necessary press the pis- • Drive out the retaining pin (1) from the wheel side. tons fully back. •...

  • Page 221: Removing And Installing Rear Brake Caliper

    S340010 Removing and installing rear brake caliper • Drain the brake system. Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid attacks paint. • Disconnect the brake line from the brake caliper. •...

  • Page 222: Disassembling And Assembling Rear Brake Caliper

    GS340140 Disassembling and assembling rear Assembling rear brake caliper brake caliper • Coat the new sealing rings with brake fluid and insert them into the left and right brake caliper Disassembling rear brake caliper bores. • Coat both brake caliper pistons with brake fluid •...

  • Page 223: Removing And Installing Front Brake Disc

    S360010 Removing and installing front brake disc • Degrease brake discs before installing. Note: Make sure the brake discs are installed the right way round (holes: see arrow). Tightening torque: (clean thread + Loctite 2701)......21 Nm Caution: Check and adjust the sensor gap. Sensor gap:..

  • Page 224: Removing And Installing Rear Brake Disc

    Removing and installing rear brake disc • Remove the brake caliper. • Remove rear wheel. S340020 • Remove brake disc. • Installation is the reverse of the removal proce- dure. • Degrease the brake disc before installing. Caution: [ABS] Check sensor gap and adjust with shims if necessary.

  • Page 225: Removing And Installing Front Abs Sensor

    S340030 Removing and installing front ABS sensor • Disengage and pull back the fuel tank. • Disconnect plug (1) of sensor cable. • Remove sensor (2) with Torx T 25. • Installation is the reverse of the removal proce- dure. Caution: Route the sensor cable correctly.

  • Page 226: Adjusting Front Abs Sensor Gap

    Torx T 25 and adjust sensor gap with shims. • Secure the dial gauge holder, BMW No. 00 2 500, with dial gauge, Sensor gap:..0.45...0.55 mm (0.018...0.022 in) BMW No. 00 2 510, and measuring shoe, BMW No. 34 2 510, to slider.

  • Page 227: Removing And Installing Rear Abs Sensor

    S340040 Removing and installing rear ABS sensor Note: When installing shims pull the sensor out only very slightly and pull the shims up and out. • Before removing/installing, clean the sensor bore. • Using Torx T 25, slacken sensor (1). •...

  • Page 228: Adjusting Rear Abs Sensor Gap

    After adjusting, rotate the wheel and check that the and extension, BMW No. 34 2 520, with dial sensor is clear at all times. gauge, BMW No. 00 2 510, firmly to the sensor mount. • Zero the dial gauge.

  • Page 229: Removing And Installing Rear Brake Master Cylinder

    Remove brake master cylinder. • Installation is the reverse of the removal proce- dure. • Secure non-reusable hose clip with pliers, BMW No. 13 1 500. S340060 Caution: • Bleed the brake system carefully. Insert a feeler gauge of the correct thickness be- Check/adjust piston rod play.

  • Page 230: Removing And Installing Footbrake Lever

    Removing and installing footbrake lever • Lubricate pivot bushing with Shell Retinax A. Caution: Check/adjust piston rod play. See removal and installation of brake master cylin- der. The brake light must come on as soon as the rear brake begins to take effect. Tightening torque: Footbrake lever to footrest assembly (clean thread + Loctite 2701).......

  • Page 231: Removing And Installing Abs Unit

    Caution: Caution: Work on the ABS unit must be performed by an au- Switch off ignition, disconnect and insulate the thorised BMW workshop. ground (earth) strap. • Remove cover (2) from ABS control unit, press Removing the ABS unit the lock in with a screwdriver and pull the cover •...

  • Page 232: Installing The Abs Unit

    Installing the ABS unit • Install the ABS unit. • Connect the central plug (5). Caution: Make sure the cable is not at an angle, or its insula- tion may be damaged. • Reconnect the 2-pin plug in the correct position, pushing the two halves fully together, and press the two wires into the center (smaller) cable en- tries.

  • Page 233: Removing And Installing Abs Relay And Relay Socket

    Removing and installing ABS relay • Tighten the nuts. and relay socket Caution: Always use new self-locking nuts. Removing ABS relay • Install a new cover (1). Caution: When sliding the cover on, make sure that all cables are correctly located in their cable entries. Scrap the old cover.

  • Page 234: Removing Abs Relay Socket

    Removing ABS relay socket • Press the contact interlock into the relay socket at the side. • Push the relay socket into the relay housing, at Caution: the same time pressing both engine cables into Switch off ignition, disconnect and insulate the the left cable entries on the relay housing (red at ground (earth) strap.

  • Page 235: Removing And Installing Brake Line

    Removing and installing brake line Removing and installing front brake line 34.21...

  • Page 236: Removing And Installing Rear Brake Line

    Removing and installing rear brake line 34.22...
  • Page 237 • Drain the brake system. Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid attacks paint. • Remove fuel tank. • Remove brake lines. • Installation is the reverse of the removal proce- dure.
  • Page 238 34.24...
  • Page 239 36 Wheels and tyres Contents Page Technical Data ..........................3 Removing and installing front wheel .................5 Removing front wheel ........................5 Installing front wheel ........................5 Removing and installing wheel bearings ................6 Removing and installing rear wheel ...................8 Static balancing of front and rear wheels ...............9 Checking front/rear wheel rim for runout ..............10...
  • Page 240 36.2...
  • Page 241 Technical Data R 1100 S Rim size Front 3.50 x 17 MT H 2 Rear 5.00 x 17 MT H 2 Option: 5.50 x 17 MT H 2 Max. radial/lateral runout Front wheel mm (in) 0.5 (0.02) Rear wheel mm (in) 0.3 (0.01) Tyre size Front 120/70 x 17 ZR17 tubeless...
  • Page 242 36.4...

  • Page 243: Removing And Installing Front Wheel

    • Place the motorcycle on the auxiliary stand, Brake caliper to fork slider tube....40 Nm BMW No. 00 1 560. • The motorcycle is heavy at the nose; if neces- sary, use a ratchet-lock belt to pull the motorcy- cle down at the rear on the lifting platform.

  • Page 244: Removing And Installing Wheel Bearings

    36 5 513 S360100 S360090 • • Clamp a drift, BMW No. 36 5 513, into the vise First insert wide bearing using drift, and place the wheel on it with the wide bearing BMW No. 36 5 512, and handle, down.
  • Page 245 00 5 500 36 5 512 36 5 513 R360028 • Clamp a drift, BMW No. 36 5 513, into the vise and place the wheel on it with the wide bearing (1) down. • Install spacer tube (2). •...

  • Page 246: Removing And Installing Rear Wheel

    00 1 560 S360040 Removing and installing rear wheel • Place the motorcycle on the auxiliary stand, BMW No. 00 1 560. • Remove rear brake caliper. Caution: Use only wheel studs with length code 55. Do not oil or grease wheel studs.

  • Page 247: Static Balancing Of Front And Rear Wheels

    36 3 600 S360050 Static balancing of front and rear wheels • Install balancing shaft, BMW No. 36 3 621, and nut, BMW No. 36 3 622, in front-wheel bearing. • Tighten nut to slightly preload bearing. • Rear wheel: mount adapter, BMW No. 36 3 618, on centring collar side with balancing shaft, BMW No.

  • Page 248: Checking Front/Rear Wheel Rim For Runout

    BMW No. 36 3 607, and nut, BMW No. 36 3 619. • Clamp locating discs (2), BMW No. 36 3 615, to the balancing shaft at left and right in such a way that the shaft cannot wander. •...
  • Page 249 46 Frame Contents Page Technical Data ..........................3 Exploded view of fairing sections ..................5 Removing and installing fairing ....................6 Removing and installing side panels ..................6 Removing and installing tank trim ...................6 Removing and installing fairing ....................6 Removing and installing rear side panels ................7 Removing and installing tail section ..................7...
  • Page 250 46.2...
  • Page 251 Technical Data R 1100 S Location of manufacturer’s type plate/frame number On frame, at right Length, overall mm (in) 2180 (85.8) Max. height without mirrors mm (in) 1160 (45.7) Width across mirrors mm (in) 880 (34.6) Width across rider’s footrests mm (in) 580 (22.8) Width across pillion footrests mm (in) 730 (28.7)
  • Page 252 46.4...

  • Page 253: Exploded View Of Fairing Sections

    Exploded view of fairing sections 46.5...

  • Page 254: Removing And Installing Fairing

    S460010 Removing and installing fairing Removing and installing fairing Removing and installing side panels • Remove side panels on both sides. • Remove mirrors. • • Remove seat. Remove the windshield. • • Remove screws securing the side panels. Disconnect headlight plug from socket at front •...

  • Page 255: Removing And Installing Rear Side Panels

    S460020 Removing and installing rear side panels • Remove securing screws at top. • Release side panel from rubber mounts. • Installation is the reverse of the removal proce- dure. Removing and installing tail section • Remove rear side panels. •...

  • Page 256: Removing And Installing Rear Mudguard

    S460030 • Removing and installing rear Remove number plate carrier. mudguard • Pull out cables. • Tap in the rubber mounts with a hammer to re- move. • • The rear silencer has to be removed to permit re- Installation is the reverse of the removal proce- moval of the rear mudguard.

  • Page 257: Removing And Installing Front Mudguard

    Removing and installing front mudguard S460040 • The front wheel has to be removed to permit re- moval of the front mudguard. Tightening torques: Mudguard to slider tube bridge ...... 8 Nm 46.9...

  • Page 258: Removing And Installing Fairing Bracket

    S460050 Removing and installing fairing bracket Tightening torques: Fairing bracket to front frame ....... 21 Nm • Switch on the ignition. • Caution: Without starting the engine, fully open the throttle Switch off ignition. once or twice so that the Motronic control unit Disconnect earth (ground) lead from battery.

  • Page 259: Removing And Installing Front Frame

    Heat leading link mount at front to max. 120 °C • Secure stand with overlength bushes, (248 °F) and unscrew. • BMW No. 00 1 520/529, to motorcycle. Release clamp securing fixed tube to upper fork • Drain the front brake system. bridge.
  • Page 260 Disconnect plug of ignition lock. • Heat screw securing ball joint to frame to max. 120 °C (248 °F) and remove, using socket and hexagon socket, BMW No. 31 5 600. • Remove fork bridge. • Remove the leading link caps.

  • Page 261: Removing And Installing Main Frame

    • Seal the fuel feed and return lines with hose Slacken nut of swinging-arm floating bearing. • clips, BMW No. 13 3 010, and remove. Loosen the floating bearing stud bolt. • • Pull the plug connector off the fuel pump unit.
  • Page 262 Remove the rear side panel on the right. • frame, if necessary using puller, Disconnect plug for rear wiring harness. • BMW No. 26 1 660, or puller with impact weight, [ABS] Disconnect sensor plug. • BMW No. 00 8 580. Disconnect plug for brake-light switch.
  • Page 263 Tightening torques: Engine to main frame M10 screw, top right (1) Initial tightening ..........13 Nm Final tightening ..........42 Nm M10 screw, top left (6)........42 Nm M10 bolts at top (struts to engine) (7) ... 50 Nm M10 screw, long, frame to gearbox (4) ..55 Nm M12 screw, bottom (8) .........

  • Page 264: Removing And Installing Frame Tail Section

    S460080 Removing and installing frame tail section Tightening torques: Frame tail section to main frame ....31 Nm Pillion footrest holder to rear frame....21 Nm • Remove seat. • Remove tail-section panels. • Remove the carrier plate for the number-plate light.

  • Page 265: Removing And Installing Side Stand

    Removing and installing side stand S460100 • Remove keeper (1) from side stand switch. • Pull off side stand switch (2). • Disconnect tension springs. • Remove side stand. Caution: Note routing of cables. Lubricant:....e.g. Staburags NBU 30 PTM Tightening torques: Side stand to pivot mount (thread cleaned + Loctite 243)......

  • Page 266: Checking Running Gear

    • Place track alignment gauge, Track offset (S): ..+ 4.5 mm (0.18 in) (= to right) BMW No. 36 3 920, against the left or right side Permissible wheel track offset (S): of the motorcycle..±9 mm (0.35 in): datum is + 4.5 mm (0.18 in)
  • Page 267 EXAMPLE: Formula: – ----- - ----- - Fixed value A (length of measuring stops) A = 50.0 mm (1.97 in) Half of rear wheel rim width ----- - = 72.5 mm (2.85 in) Measured value B (mean value) B = 70.0 mm (2.76 in) Half of front wheel rim width = 54.5 mm (2.16 in) ----- -...
  • Page 268 46.20...
  • Page 269 51 Equipment Contents Page Removing and installing ignition switch/steering lock ...........3 Removing and installing ignition/light switch ..............3 Removing and installing lock barrel ..................3 Drilling out lock barrel ..........................3 Removing and installing dualseat lock ................3 Removing and installing lock barrel for fuel tank filler cap ........4 Drilling out lock barrel ..........................4 51.1...
  • Page 270 51.2...

  • Page 271: Removing And Installing Ignition Switch/Steering Lock

    • Install steering lock with non-removable socket Drilling out lock barrel • wrench insert, BMW No. 51 0 531. Use a 4-5 mm (0.16-0.20 in) dia. drill bit to drill the full length of the lock barrel. • Tightening torques:...

  • Page 272: Removing And Installing Lock Barrel

    GS510040 Removing and installing lock barrel for fuel tank filler cap Note: Make sure that screws do not fall into fuel tank: cov- er fuel tank filler neck with cloth. • Open cap and remove lower part of cap (1). •...
  • Page 273 52 Seat Contents Page Removing and installing seat ....................3 52.1...
  • Page 274 52.2...
  • Page 275 S520010 Removing and installing seat 52.3...
  • Page 276 52.4...
  • Page 277 61 General electrical equipment Contents Page Technical Data ..........................3 Relay positions (central electrical equipment box) ...........5 Fuse assignments ..........................5 Left fuse box ............................5 Right fuse box .............................5 Frame wiring harness ........................6 Wiring harness View from left ............................7 Wiring harness View from right ..........................11 61.1...
  • Page 278 61.2...

  • Page 279: Technical Data

    Technical Data R 1100 S Battery Option: 61.3...
  • Page 280 61.4...

  • Page 281: Relay Positions (Central Electrical Equipment Box)

    S610010 Relay positions (central electrical Fuse assignments equipment box) Left fuse box (No. 1 on left, looking forwards) 1. ABS warning relay 2. Relief relay 1. Instrument panel, controller for fuel 3. Horn relay warning lamp or indicator damping, 4. Indicator damping brake light ..........

  • Page 282: Frame Wiring Harness

    Frame wiring harness Caution: Use (yellow) galvanized screws for the ground (earth) connection to the engine. Screws with unsuitable corrosion proofing can cause the electrical resistance to rise as high as Run wiring without kinking and avoid risk of abra- sion.

  • Page 283: Wiring Harness

    Wiring harness View from left S619010 61.7...
  • Page 284 S619011 61.8...
  • Page 285 S619012 61.9...
  • Page 286 S619013 61.10...

  • Page 287: Wiring Harness View From Right

    Wiring harness View from right S619020 61.11...
  • Page 288 S619021 61.12...
  • Page 289 S619022 61.13...
  • Page 290 S619023 61.14...
  • Page 291 62 Instruments Contents Page Technical Data ..........................3 Removing and installing instrument panel ..............5 Disassembling and assembling instrument panel .............5 62.1...
  • Page 292 62.2...
  • Page 293 Technical Data R 1100 S Instrument cluster Instrument lighting T6.5 12 V 3 W Telltale and warning lights T6.5 12 V 1.7 W 62.3...
  • Page 294 62.4...
  • Page 295 S620010 Removing and installing instrument panel • Remove side panels. • Remove mirrors. • Remove fairing. • Open electrics box on right. • Disconnect plug of instrument panel. • Remove fuses from instrument panel. • Remove instrument panel. • Installation is the reverse of the removal proce- dure.
  • Page 296 62.6...
  • Page 297 63 Lights Contents Page Technical Data ..........................3 Removing and installing headlight ..................5 Adjusting headlight ........................5 63.1...
  • Page 298 63.2...
  • Page 299 Technical Data R 1100 S Headlight Twin halogen headlights Low (dipped) beam headlight: Projection type High (main) beam headlight: Free-form type Bulbs Low (dipped) beam headlight H 1 halogen bulb, 12 V 55 W High (main) beam headlight H 7 halogen bulb, 12 V 55 W Parking light 12 V/5 W Standard designation W 5 W...
  • Page 300 63.4...
  • Page 301 S630010 Removing and installing headlight Caution: Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. Do not touch inner surface of reflector or bulbs with bare hands. • Remove side panels. • Remove mirrors. • Remove the windscreen. •...
  • Page 302 63.6...

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