Page 3 - TABLE OF CONTENTS
3 TABLE OF CONTENTS R1100 CHECKLIST - CARL KULOW .........................................................................................................................................4 R1100 PARTS AND TOOL LIST - CARL KULOW ............................................................................
Page 4 - R1100 Checklist - Carl Kulow; Tools
4 R1100 Checklist - Carl Kulow • Check alternator belt (replace 36K miles) • Adjust valves • Spark plugs (replace 12K) • Air filter (replace 12K) • Lube and adjust clutch cable • Lube front shock lower mount • Lube side and center stand • Check brake fluid (replace yearly) • Check brake pads • Check...
Page 5 - R1100 Maintenance Steps - Carl Kulow; Check Alternator Belt
5 R1100 Maintenance Steps - Carl Kulow Note: This overview section serves only as a step by step reminder for experiencedworkers. If you are unfamiliar with any procedure you should read the parentheticalreference article or Paul Glaves’ Routine R1100 Service Article! Note to R1100RT and R1100RS Rid...
Page 6 - grease fitting on some RS’s only, others lube with WD40 if necessary
6 Lube and Adjust Clutch Cable adjust maximum slack at clutch lever, at rear of transmission pry clutch release arm torelease the clutch cable there, lube both ends of clutch cable with BMW #10 grease,reattach cable, using the knurled adjuster at the hand lever adjust to 12mm between itand the knurl...
Page 8 - R1100 Routine Service – Paul Glaves; Inspection I
8 R1100 Routine Service – Paul Glaves In this article we will cover the specifications and other information needed for a mechanicallyexperienced R1100 owner to perform routine maintenance on his or her motorcycle. Thisarticle is not intended to teach the mechanically inexperienced owner everything ...
Page 10 - Check and Adjust the Alternator Drive Poly Belt:; The alternator drive belt is located behind; Check the Spark Plugs:; The spark plugs should be visually examined each Minor Service.; Check the Brake Pads:; Remove the brake caliper covers (lightly spread the cover using a
10 Check Battery: Inspect the battery to ensure that the electrolyte level is between the minimum and maximum marks. Top off to the maximum mark with distilled water. Check theconnections for signs of corrosion. Clean the terminals and connections as required. Check and Adjust the Alternator Drive P...
Page 11 - Check the Brake Rotors:; Examine the brake disks for scoring and wear. BMW specifies a; Grease the Side Stand and Center Stand:; Grease the side stand and center stand (some; Synchronize the Throttle Bodies:; Adjust the choke cable so there is approximately 1mm; Lubricate the Lower Front Shock Mount:; Remove the lower front shock mounting bolt and
11 Check the Brake Rotors: Examine the brake disks for scoring and wear. BMW specifies a minimum thickness of 4.5 mm (.17 inches) for the front rotors and 4.6 mm (.18”) for the rearrotor. Carefully examine the “rivets” which attach the front floating disks to their carriers.These wear, and need to b...
Page 12 - Change the Transmission Oil:; With the bike fully warmed up, drain the transmission oil and; Change the Final Drive Oil:; With the bike fully warmed up, drain the final drive oil and refill; Renew the Air Filter.
12 MAJOR SERVICE: For a Major Service, perform all of the service items called for in a minor service, and inaddition perform the following: Change the Transmission Oil: With the bike fully warmed up, drain the transmission oil and refill the transmission. The fill plug is readily identifiable on th...
Page 13 - Check the Brake Fluid Level:; Check the level of the brake fluid in the reservoirs and top off; Renew the Spark Plugs:; The spark plugs should be replaced at the Major Service interval.
13 Check the Brake Fluid Level: Check the level of the brake fluid in the reservoirs and top off to the maximum fill line with DOT 4 brake fluid. You should plan on changing the brake fluid atleast once each year, regardless of mileage. BMW specifies that when changing brake fluid orflushing the sys...
Page 14 - Alternator Belt Adjustment - Jon Diaz
14 Alternator Belt Adjustment - Jon Diaz The following is not BMW factory procedure....use at your own risk. I remove the left fairing panel, the airbox horn, and the front cover on the engine block.The belt needs to be tightened with a 6mm allen wrench from the rear (airbox) side ofthe alternator. ...
Page 17 - Clutch Adjustment - Paul Glaves
17 Clutch Adjustment - Paul Glaves The clutch adjustment at the hand lever specified as 7mm when resistance is felt is abit deceptive, or at least ambiguous. Proper clutch adjustment procedure - whichBMWNA says is critical to proper clutch operation is: a. adjust the knurled adjuster at the hand gri...
Page 18 - Clutch Adjustment - Bob Gorman
18 Clutch Adjustment - Bob Gorman A just released service bulletin revises the clutch freeplay specification to 12mmbetween the knurled nuts and 7mm at the lever. This is revised from 10mm and 5mmrespectively. It appears that improper clutch adjustment has been the cause of many shiftingproblems. In...
Page 22 - TROUBLE SHOOTING
22 After the fluid has been completely replaced and all nipples are tight, check that the front andrear reservoirs are filled and secure. Slowly pump the brake lever, then pump the foot pedaluntil there is a solid feel. Continue pumping the brakes for a few minutes, then recheck thereservoir level a...
Page 24 - Brake Pad Replacement - Carl Kulow; repeat for other front caliper
24 Brake Pad Replacement - Carl Kulow Many riders are particularly pleased with EBC pads which can be ordered through anymotorcycle dealer from Tucker-Rocky. Front Pads (2 sets) - - - - - all R1100’s = EBC # FA246 Rear Pads - - - - - - - - - - - - GS, R, RT = EBC # FA245 - - - - - - - - - - - - - - ...
Page 26 - Spongy Brakes Fix – Simon Evans; So here’s the quick step by step 30 second fix:
26 Spongy Brakes Fix – Simon Evans Fiddling with the R1100GS this morning, I removed the handguards for cleaning and to top upthe brake master cylinder (the spate of warm weather in the UK having caused a re-ocurrenceof that perennial old bugbear - the “Spongy brake – or the ohmigodthelevercumsbackt...
Page 27 - Changing the Fuel Filter on an R1100RS - Jon Diaz
27 Changing the Fuel Filter on an R1100RS - Jon Diaz Here is the procedure to change your R1100RS fuel filter. It took me about 90 minutesthe first time....but hopefully, things will go more quickly for you! Purchase the following before you start: a new fuel filter, a new sealing O-ring for thefuel...
Page 28 - R1100 Lube Change Tool - Mick McKinnon; Crude ASCII ART:
28 groove, the vent lines forced back on the plate, and install the plate exactly asremoved. Start all six screws, and tighten in a cross pattern. I tilted the tank back upafter this operation to try and get the O-ring to leak. After 30 minutes or so, nothinghad come out. I would suggest doing this ...
Page 29 - Synchronizing R1100 Throttle Bodies - Bob Gorman
29 Synchronizing R1100 Throttle Bodies - Bob Gorman This is and will continue to be a hot topic amongst R1100 owners. Properly synchedthrottle bodies will greatly reduce surging and vibration but getting them synched andkeeping them synched is probably the most difficult of any BMW motorcycle to dat...
Page 30 - Throttle Body Sync - Jon Diaz; How To Synch Those R1100 Throttle Bodies!
30 rpm's, as this can potentially suck mercury into the motor. If you need to make anadjustment loosen, or slacken in BMWese, the 10mm lock nut on the cable nipple. Turnthe cable nipple in or out being careful not to turn the cable housing at the same time.Keep checking to make sure the cable turns ...
Page 31 - to provide a little cooling breeze and temperature stability.
31 to provide a little cooling breeze and temperature stability. After the warm-up ride, place the bike on the centerstand. Remove the black plasticinjector covers if your bike has them, remove the vapor recovery tubes from the bottomside of each injector body, and insert the hoses from the Carb Sti...
Page 32 - Throttle Body Synch for Dummies – Stephen Karlan (Dali Meeow); The throttle bodies will be synched at two rpm levels.
32 Throttle Body Synch for Dummies – Stephen Karlan (Dali Meeow) An out-of-synch condition develops (R850 and R1100) because the throttle body cablesstretch or because they lose their adjustment. The result is vibration, sometimes unrealvibration. The following procedure, which I call the Gorman/Dia...
Page 33 - Starting the Adjustment:
33 There is one black tube attached to the under side of each throttle body. Remove both black(vapor recovery) tubes and you will expose the brass nipples that point down. Attach one ofthe carb stix's flexible plastic tubes to each brass nipple. Make certain that the carb stix'splastic tubing does n...
Page 34 - Ask you favorite cycle shop or mail order company for their price.
34 HIGH RPM SYNCH: When performing the high rpm synch, you will be moving the throttle up to4,000 rpm. Move the throttle slowly to avoid sucking mercury into the engine. The right side crossover synch cable has already been loosened ['97- right throttle cable hasalready been loosened]. The knurled k...
Page 35 - LBBS Large Brass Bypass Screw:
35 If the mercury comes out of the reservoir (because it tipped over or the cat hit it), you can get itfrom Chaparral Motorsports 1-800-841-2960 part# 315-0441 for $9.99.~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ Glossary: RSCSC Right side crossover synch cable ['97- right throt...
Page 36 - Throttle Position Sensor - Bob Gorman
36 Throttle Position Sensor - Bob Gorman The throttle position sensor is located on the left throttle body. It is the black boxwith an electrical plug extending from the bottom. The sensor is what ties themechanics of the throttle cable to the electronics of the Motronic. The Motronic needs to know ...
Page 37 - Throttle Position Sensor - Rob Lentini; Performance-wise here is what I observed and concluded:
37 Throttle Position Sensor - Rob Lentini Note: the following information has been updated in the “R1100 Throttle PositionSensor Tuning” article in the Super Tuning section of this manual. The followinginformation is intended primarily for people who wish to adjust their TPS but donot want to change...
Page 39 - 2 Steps to Throttle Set Screw / TPS Adjustment
39 This article does not present significant or new procedures, it has been written fornewbies and simply goes into greater detail. It was designed to help you find the rightpart to tweak. These instructions assume that you know almost nothing about the bike,where parts are located, or how it functi...
Page 45 - Oil Change - Paul Glaves
45 Oil Change - Paul Glaves 1. Warm up engine thoroughly2. Turn off engine3. Place motorcycle on center stand4. Place drain pan under the drain plug in the bottom of the oil pan5. Remove oil filler plug to let air into crankcase6. Take 8mm allen wrench and carefully remove the plug without burningyo...
Page 46 - Leaking Cam Covers and Oil filler Cap - Stephen Karlan (Dali Meeow); REPLACING THE OIL FILLER O RING.
46 Leaking Cam Covers and Oil filler Cap - Stephen Karlan (Dali Meeow) If you own an R850 or R1100 BMW and there is excessive grime or some messyoil leaks around the oil filler cap or the black plastic cam covers at the rear of thecylinders, then your bike might benefit from some high temperature O ...
Page 48 - R1100RS Driveshaft And Clutch Spline Lube - Kit Vercella; Be organized. Make notes and label parts if necessary.
48 R1100RS Driveshaft And Clutch Spline Lube - Kit Vercella First a few introductory comments are in order. The following procedure is the result ofhaving done this particular service only once. It is certainly possible that those whohave more experience can offer some refinements to the procedure b...
Page 51 - See ya back here in another 40,000 miles.
51 At this point I don’t recall whether I was able to remove the air box assembly, orwhether the rear frame had to be partially tilted upward first. (Hey, remember I only didthis once). But, it should be obvious to you once you have reached this point. Unless I have forgotten something, you’re now r...
Page 53 - Super; R1100 Throttle Position Sensor Tuning - Rob Lentini; Background
53 Super Tuning! R1100 Throttle Position Sensor Tuning - Rob Lentini Background Since the "R1100 Fuel Injection/Surging/Fixes" series I have continued toinvestigate how the Throttle Position Sensor (TPS) works. My aim was todevelop the best procedure for a curious, competent home mechanic to...
Page 54 - Procedure; AND, IF YOU HAVE NO COMPLAINTS WITH YOUR BIKE, LEAVE IT ALONE!
54 this was a good starting point. What is the standard opening fixed by the bluepaint? Is it air flow, gap between the butterfly and bore or, arghhh(!) "x" numberof turns from full closed? I wondered, if .370-.400 volts "should" be whatequates to a proper opening for idle, perhaps s...
Page 57 - Advanced Ignition Timing - Rob Lentini
57 at all. Another cable enters the distribution box from the start lever. Whenactuated, this cable pulls a tab across that contacts a flange on the wheel,opening the throttles a prescribed amount for starting. So the cable at each throttle body is just that, the throttle cable for that particularsi...
Page 58 - Valve Lash Increase - Rob Lentini
58 the idle RPM is 1000 or less! If your R1100 is like mine, the timing will beadvanced 50% further than the "OT" to "S" mark, for about 9 degrees of initialadvance. If so, put everything back together and, if during your test ride youdetect no noticeable detonation, you are in busin...
Page 61 - THROTTLE BODY BUTTERFLY BUSHING/SEAL WEAR
61 THROTTLE BODY BUTTERFLY BUSHING/SEAL WEAR - Rob Lentini Problems with throttle body synchronization and accomplishment of "zero=zero"may, but rarely, be caused by wear or failure of the throttle butterfly shaftbushings and/or seals. While these parts are not currently available forreplace...
Page 62 - R1100 Tire Change - Carl Kulow; Front Wheel Removal
62 R1100 Tire Change - Carl Kulow Front Wheel Removal before removing, check rim for dents!!! out of round and runoutRS: remove fender and fork covers - top=3mm, side=5mm and 3mmremove both sets of calipers - bolts through forks, 8mm (rock back and forth onrotor to spread pads for easy removal)remov...
