BMW R850, R850R, R850GS, R1100GS, R1100R, R1100RS, R1100RT, R1100S, R1150GS Adventure, R1100R Rockster, R1150RS, R1100RT, R1200C Repair Manual 1993-2005

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Item # M503-3  ISBN: 9781599690407




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This repair manual covers BMW R Series models 1993-2005, and provides complete repair, tune-up, service and maintenance information for the engine, clutch and transmission, plus coverage on the fuel system, emission control, exhaust systems, front suspension and steering, rear suspension and final drive, brakes, body and rear frame, and electrical system with color wiring diagrams.

Models Covered

• R850R 1996-1998 US, 1995-2001 UK
• R850C 2000-2001 UK
• R850GS 2000-2001 UK
• R1100GS 1995-1999 US, 1994-2000 UK
• R1100R 1995-2001 US & UK
• R1100RS 1993-2001 US, 1993-2002 UK
• R1100RT 1996-2001 US, 1995-2001 UK
• R1100S 1999-2005 US, 2000-2004 UK
• R1150GS/Adventure 2000-2005 US, 1999-2004 UK
• R1150R/Rockster 2002-2005 US, 2000-2004 UK
• R1150RS 2002-2004 US, 2001-2003 UK
• R1150RT 2002-2004 US, 2000-2004 UK
• R1200C 1998-2004 US & UK

Note: This manual is not specific to R1200CL or R1200C Montauk models.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual Organization | Warnings, Cautions, and Notes | Safety | Serial Numbers | Fasteners | Shop Supplies | Basic Tools | Precision Measuring Tools | Electrical Fundamentals | Basic Service Methods | Storage

CHAPTER TWO: TROUBLESHOOTING
Operating Requirements | Starting The Engine | Starting Difficulties | Engine Performance | Engine Noises | Engine Lubrication | Cylinder Leakdown Test | Clutch | Transmission | Final Drive | Electrical Testing | Lighting System | Starting System | Charging System | Ignition System | Front Suspension and Steering | Brake System

CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP
Fuel Type | Pre-Ride Check List | Tires and Wheels | Battery | Engine Oil and Filter | Transmission | Final Drive | Control Cable Service | Rear Brake Pedal Pivot Shaft Bolt and Bushing Lubrication | Shift LeverCleaning and Lubrication | Sidestand | Windshield Adjust Shaft (RS Models) | Air Filter | Brake System | Clutch | Fuel Filter Replacement | Fuel Hose Inspection | Crankcase Breather Inspection | Evaporative Emission Control System | Exhaust System | Handlebars | Handlebar Grips | Front Suspension Inspection | Rear Suspension Inspection | Rear Frame Inspection | Fastener Inspection | Tune-Up Procedures | Cylinder Head Fasteners | Valve Clearance | Ignition Timing | Engine Compression Test | Spark Plugs (Single Plug Ignition System) | Spark Plugs (Dual-Plug Ignition System) | Spark Plug Inspection | Throttle And Choke Cable Adjustment (All Models Except R850C and 1200C Models) | Throttle Cable Adjustment (1993-1995 R850C and R1200C Models) | Throttle Body Synchronization and Idle Speed Adjustment | Alternator Drive Belt Adjustment

CHAPTER FOUR: ENGINE TOP END
Engine Service Notes | Cylinder Head Cover | Cylinder Head | Valve Gear Holder | Valves and Valve Components | Cylinder and Piston | Piston and Piston Rings

CHAPTER FIVE: ENGINE LOWER END
Engine Service Notes | Servicing The Engine In Frame | Engine (GS, R, RS and RT Models) | Engine (R1100S Models) | Engine (R850C and R1200C Models) | Alternator Support Cover | Auxiliary Drive Shaft Mechanism | Oil Pump | Crankcase | Rear Main Seal Replacement | Auxiliary Drive Shaft, Camshaft Chains and Tensioner Assemblies | Crankshaft | Connecting Rods | Oil Coolers and Hoses | Engine Break-In

CHAPTER SIX: CLUTCH
Clutch | Clutch Release Mechanism (Cable Operated Models) | Clutch Cable | Clutch Master Cylinder | Clutch Release Cylinder | Clutch System Hydraulic

CHAPTER SEVEN: FIVE-SPEED TRANSMISSION and GEARSHIFT MECHANISMS
Transmission Case | Neutral Switch and Gear Position Switch | Transmission Housing Cover | Transmission Shafts and Gearshift Mechanism | Transmission Shafts | Gearshift Mechanism | Transmission Housing, Housing Cover Bearings and Seals

CHAPTER EIGHT: SIX-SPEED TRANSMISSION and GEARSHIFT MECHANISMS
Transmission Case | Neutral | Gear Position Switch | Transmission Housing | Transmission Shafts and Gearshift Mechanism | Transmission Housing and Housing Cover | Transmission Shafts | Gearshift Mechanism | Transmission Housing and Housing Cover Oil Seals

CHAPTER NINE: FUEL, EMISSION CONTROL and EXHAUST SYSTEMS
Motronic System | Fuel Injection System Components | Depressurizing The Fuel System | Fuel Injection System Precautions | Fuel Injectors | Throttle Body | Pressure Regulator | Motronic Control Unit | Throttle Position Sensor | Air Filter Assembly | Throttle Cables | Increase Idle (Choke) | Cable Replacement (All Models Except R850C and R1200C) | Fuel Tank | Rollover Valve (All R1150 Models) | Fuel Filter Replacement | Fuel Pump | Fuel Pump Pressure Test | Fuel Level Sending Unit | Crankcase Breather System (U.S. Models Only) | Evaporative Emission Control System (California Models Only) | Exhaust System

CHAPTER TEN: ELECTRICAL SYSTEM
Electrical Component Replacement | Charging System | Alternator | Ignition System | Hall Sensor Unit | Main Ignition Coil | Direct Ignition Coils | Spark Plug Secondary Wires | Spark Plug Primary Wires (Dual-Plug Models) | Starting System | Starter | Starter Relay | Lighting System | Headlight | Taillight | Brake Light And License Plate Light | Turn Signals | Switches | Rider Information Display (RID) (1993-1998 GS, RS and RT Models) | Instrument Panel | Central Electrical Equipment Box or Modules | Relays | Fuses | Battery Case | Horn | Wiring Diagrams

CHAPTER ELEVEN: WHEELS, HUBS and TIRES
Front Wheel | Rear Wheel | Front Hub | Wheel Runout And Balance | Spoke Wheel Service | Tire Changing | Tire Repairs

CHAPTER TWELVE: FRONT SUSPENSION and STEERING
Handlebar | Handlebar Controls | Handlebar Lever | Clearance Adjustment (R1100S and All R1150 Models) | Upper Fork Bridge | Lower Fork Bridge | Front Fork (GS, R, RS and RT) | Front Fork (R1100S) | Front Fork (R850C and R1200C) | Front Fork Overhaul (All Models) | Front Strut Adjustments | Front Strut | Front Suspension A-Arm | Steering Damper (R1100R Models)

CHAPTER THIRTEEN: REAR SUSPENSION and FINAL DRIVE
Shock Absorber | Swing Arm and Drive Shaft (Paralever Models) | Final Drive Unit (Paralever Models) | Swing Arm and Drive Shaft (Monolever Models) | Final Drive Unit (Monolever Models) | Final Drive Overhaul (All Models) | Pinion Gear-To-Ring Gear Adjustment (All Models) | Tapered Roller Bearing Preload

CHAPTER FOURTEEN: BRAKES
Brake Fluid Selection | Preventing Brake Fluid Damage | Brake Service | ABS II System | Integral ABS System | Brake Pads | Brake Calipers | Caliper Overhaul | Brake Fluid Filler Adapter | Front Master Cylinder (R850R and All R1100 Except R1100S) | Front Master Cylinder (R850S, R1100S, R1150 and R1200C) | Rear Master Cylinder | Brake Disc and Sensor Wheel | ABS Sensor | ABS Unit (ABS II Models) | ABS Pressure Modulator (Integral ABS Models) | ABS Relay (ABS II) | Brake Hose and Line Replacement | Rear Brake Pedal | Brake Bleeding (Non-ABS and ABSII Models) | Brake Bleeding (Integral ABS Models)

CHAPTER FIFTEEN: BODY and FRAME
Seat | Seat Backrest (R850C and R1200C Models) | Front Fender and Mud Guard | Rear Fender and Mud Guard | Body Side Panels (R Models) | Windshield (GS Models) | Body Panels (RS Models) | Body Panels (RT Models) | Body Panels (R1100S Models) | Luggage And Luggage Carrier | Windshield Cleaning (All Models) | Sidestand | Centerstand | Footrests (R1100GS, R1100R and R1100RS Models) | Footrests (R1150R and R1150RS Models) | Footrests (R1150GS Models) | Footrest (RT Models) | Footrests (R1100S Models) | Footrests (R850C and R1200C Models) | Front Safety Bars | Handle (RT Models) | Engine Guard | Main Frame (R1100S Models) | Front Frame (R850C and R1200C Models) | Rear Frame | Raising Rear Frame

COLOR-CODED WIRING DIAGRAMS

BMW R850, R850R, R850GS, R1100GS, R1100R, R1100RS, R1100RT, R1100S, R1150GS Adventure, R1100R Rockster, R1150RS, R1100RT, R1200C Repair Manual 1993-2005