Valkyrie Oilhead Maintenance Manual 2 25 02

User Manual: Oilhead Maintenance Manual Troubleshoot Oilhead Maintenance |

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Oilhead
Maintenance
Manual
R850, R1100, R1150, R1200
Internet BMW Riders and Oilhead Riders
2
Edited by Carl Kulow
Send comments/corrections to
kulowc@indiana.edu
ISBN R-850-1100-1150-1200
Third Edition
2-25-02
Copyright: IBMWR and Oilhead Riders
The authors have done their best to produce accurate information. However, they
assume no liability for any damage or injury caused by any errors or omissions in
this manual. Use at your own risk.
3
TABLE OF CONTENTS
Section I – by Carl Kulow
MAINTENANCE SCHEDULE.................................................................................................................................................6
PARTS AND TOOL LIST .......................................................................................................................................................7
Cold Engine and Drivetrain Procedures
ALTERNATOR BELT.............................................................................................................................................................8
VALVE ADJUSTMENT ..........................................................................................................................................................9
SPARK PLUGS ....................................................................................................................................................................12
AIR FILTER ..........................................................................................................................................................................13
LUBE SIDESTAND AND CENTERSTAND .........................................................................................................................14
CLUTCH CABLE..................................................................................................................................................................14
BRAKE AND CLUTCH FLUID.............................................................................................................................................15
BRAKE PADS ......................................................................................................................................................................16
BATTERY INSPECTION ......................................................................................................................................................17
FUEL FILTER .......................................................................................................................................................................18
MISCELLANEOUS...............................................................................................................................................................19
SUMP GUARD REMOVAL ..................................................................................................................................................20
TEST RIDE ...........................................................................................................................................................................20
Hot Engine and Drivetrain Procedures
THROTTLE BODY SYNC ....................................................................................................................................................21
ENGINE OIL AND FILTER CHANGE ..................................................................................................................................23
TRANSMISSION GEAR OIL CHANGE ...............................................................................................................................24
REAR WHEEL DRIVE GEAR OIL CHANGE ......................................................................................................................25
SUMP GUARD INSTALLATION ..........................................................................................................................................25
Other procedures
BRAKE PAD REPLACEMENT ............................................................................................................................................26
TIRE CHANGE .....................................................................................................................................................................28
4
TABLE OF CONTENTS (CONTINUED)
Section II – by Various Authors
ROUTINE R1100 SERVICE - PAUL GLAVES.....................................................................................................................32
VALVE ADJUSTMENT - STEPHEN KARLAN ....................................................................................................................38
CLUTCH ADJUSTMENT - PAUL GLAVES.........................................................................................................................40
CLUTCH ADJUSTMENT - BOB GORMAN.........................................................................................................................41
BRAKE BLEEDING - STEPHEN KARLAN .........................................................................................................................42
CHANGING THE FUEL FILTER ON AN R1100RS - JON DIAZ.........................................................................................47
EXTRNAL FUEL FILTER MODIFICATION - ROB LENTINI ...............................................................................................49
SYNCHRONIZING R1100 THROTTLE BODIES - BOB GORMAN.....................................................................................53
THROTTLE BODY SYNC - JON DIAZ ................................................................................................................................54
THROTTLE BODY SYNCH - STEPHEN KARLAN ............................................................................................................56
THROTTLE POSITION SENSOR - BOB GORMAN............................................................................................................60
THROTTLE POSITION SENSOR - ROB LENTINI ..............................................................................................................61
THROTTLE SCREW AND TPS ADJUSTMENT - STEPHEN KARLAN ............................................................................62
THROTTLE CABLE AND CHOKE CABLE REPLECEMENT - BRYAN LALLY ................................................................69
MOTRONIC FAULT CODES -STEFAN HEGNAUER..........................................................................................................71
LED FAULT CODE READER - HENRY DE KUIJER ..........................................................................................................73
ANALOG FAULT CODE READER - ROB LENTINI............................................................................................................73
DRIVESHAFT AND CLUTCH SPLINE LUBE - KIT VERCELLA ........................................................................................74
Section III - Super Tuning! by Rob Lentini
ZERO = ZERO THROTTLE POSITION SENSOR TUNING ...............................................................................................79
ADVANCED IGNITION TIMING...........................................................................................................................................81
VALVE LASH INCREASE....................................................................................................................................................82
RESULTS OF INCREASED VALVE LASH AND ADVANCED TIMING .............................................................................82
NON-OEM PLUGS FOR THE R1100/850 OILHEADS ........................................................................................................83
THROTTLE BODY BUTTERFLY BUSHING/SEAL WEAR.................................................................................................85
GS INTAKE MANIFOLDS AND CAT CODE PLUG HOP UP AN R1100RS/RT...............................................................86
5
Introduction
There are three main sections to this manual as follows:
Section I – by Carl Kulow
This section consists of basic maintenance procedures that were done on an
R1150GS, 2001. Once you remove the various plastic covers from an R, RT or
RS, the procedures should essentially be identical to those given here.
Section II – by Various Authors
Generally, this section contains more detailed instructions than those found in
Section I, especially Stephen Karlan’s very detailed write-ups. This section also
contains procedures that are not part of the normal maintenance schedule.
Section III – by Rob Lentini
This section is the real masterpiece of this manual, containing Rob Lentini’s
“Zero = Zero” surging fix and other gems.
Note to RT and RS Riders: for many of the following procedures, you will need to
remove the side panels as described in your owners manual “Service and
Technical Booklet” except RT: instead of pulling the mirror off as the manual
says, hold the back of the mirror (front of bike) with one hand while you hit the
front outside corner of the mirror with the palm of your hand thus knocking the
mirror off.
Note: When performing maintenance on your bike, be sure that you consult
multiple sources of information such as your owner’s manual, www.ibmwr.org/,
and the various bike specific lists. Haynes, Clymer, and BMW have maintenance
manuals with pictures and instructions that are invaluable – get one of each for
your bike.
6
Service – Every 6K Miles
Engine oil and filter - change
Brake fluid – check
Brake pads – check
Clutch fluid – check
Sidestand – grease
Sidestand switch – check
Spark plugs – check
Valves – adjust
Throttle cables – check
Throttle Bodies - synchronize
Inspection – Every 12K Miles
Transmission gear oil – change
Rear drive gear oil – change (every 24K miles)
Fuel filter – change (every 24K miles)
Battery fluid level – check
Battery – electrolyte level, clean/grease terminals
Air filter – change
Alternator belt – change (every 36K miles, some R1100 at 24K miles)
Wheel bearing play – check
Swing arm bearing play – check
Spark plugs – change
Annual Service
Brake fluid – change
Clutch fluid – change (every 2 years)
7
TOOLS
socket set, metric
hex bit socket set (allen), metric (Sears)
ratchet
extensions
wrenches – open end/box, metric
hex wrenches (allen T-handle), metric
torque wrench
pliers
screwdrivers
feeler gauges
oil filter wrench
oil drain pan
motorcycle toolkit (BMW)
rubber gloves (dishwashing)
flashlight, minimag
measuring cylinder (photo store)
Twin Max or carb stix
Mityvac or “one man brake bleeder”
tire change tools (see tire change instructions)
PARTS
Parts Misc.
spark plugs compressed air
oil filter anti seize paste
air filter carb or brake cleaner
brake pads rags
oil - 4 qt. BMW #10 grease
gear oil - 1 1/4 qt. flexible tubing (tygon)
alternator belt grease
fuel filter, o-ring, clamps chain lube
crush washers for: brake fluid (DOT 4)
- oil drain plug distilled water
- transmission fill and drain plugs
- rear drive fill and drain plugs
8
Cold Engine and Drivetrain Procedures
Check Alternator Belt
Tools Parts
T-handle hex – 4mm none
Note: In most cases the alternator belt does not need to be checked any more.
Early models should have the pulley and belt upgrade that came out a few years
ago. Current recommendations are that the belt is installed and adjusted, then
not disturbed until 36K when replacement is specified.
1. Remove the four bolts holding the black plastic alternator belt cover at the front
of the engine, 4mm T-handle hex.
2. Remove the cover by sliding it straight down.
3. Check the belt for cracks or shredding.
4. Check the belt tension, quite tight, ~1/4” deflection when you press on the
center.
Note: Paul Glaves suggests that proper belt tension is when you can twist the
belt ~90 degrees, midway between the pulleys. If you can twist it more than 90
degrees, it is too loose. If you cannot twist it 90 degrees, then it is too tight.
5. Leave the cover off for the valve adjustment procedure on the next page.
Change Alternator Belt
Tools Parts
T-handle hex – 4mm alternator belt
socket – 13mm
ratchet
wrench – 13mm
torque wrench
1. Remove the four bolts holding the black plastic alternator belt cover at the front
of the engine, 4mm T-handle hex.
2. Remove the cover by sliding it straight down.
3. Loosen the 2 nuts and 1 bolt, 13mm, that hold the alternator – one is on top
and one is on each side, thus allowing the alternator to pivot down.
4. Remove the old belt. (Some bikes have a pipe that traps the belt – loosen it
enough to get the old belt out and the new belt in)
5. Install the new belt being sure it is properly seated.
6. BMW calls for a tensioning torque of 5.9 ft.lb. (8 Nm) on the adjuster bolt on
the left side of the bike. You have to get at this bolt from the alternator side and
you may have to lift the tank. Alternatively, you can pry the alternator up with a
large screwdriver to tension the belt.
7. Once the belt is under proper tension, tighten the 2 nuts and 1 bolt, 13mm, to
15 ft.lb. (20 Nm).
8. Check the belt for proper tension (see above) and proper seating alignment.
9
Valve Adjustment
Tools Parts
T-handle hex – 3mm, 5mm, 6mm none
plug wire cap puller
sparkplug socket
short extension
ratchet
rag
hex socket - 6mm
long thin screwdriver
box wrench – 10mm, 16mm (17 will work)
small flashlight
feeler gauges
sharp awl
1. Remember – engine cold!
2. Bike on centerstand.
3. Transmission in neutral.
4. Remove the black plastic valve cover protectors, if installed, using a 5mm T-
handle hex wrench.
5. Remove the black valve cover strip by pulling outward on the end where the
plug wire goes under it.
6. Pull the plug wire cap off the sparkplug using the special black plastic tool in
your BMW tool kit.
7. Before removing the sparkplug, blow compressed air around the plug well –
there is often dirt here that can fall into the cylinder when you remove the spark
plug!!!
Note: If you do not have an air compressor, you can get a compressed air tank at
any Xmart automotive department, or you can get a small can of compressed air
at any photo or computer supply store.
8. Repeat again after turning the spark plugs a couple of turns.
9. Remove the spark plugs using the tool kit spark plug socket or 5/8 in. deep
well very thin wall socket.
Warning!: It is very easy to get a spark plug socket stuck in the plug well. If your
socket does not slide onto the spark plug easily, do not use it!!! Use the spark
plug socket in the BMW tool kit instead. I welded a nut onto the end of my BMW
socket so I could use a torque wrench on it when installing the spark plugs.
10. Place an oil drain pan under the valve cover.
11. Remove both valve covers using a 6mm hex socket and ratchet.
Note: Loosen the valve cover bolts until you can pull them part way out. They
stay in the valve cover – do not try to pull them all the way out.
10
Note: The valve covers may stick slightly and you will need to tap them firmly
with the palm of your hand or a rubber mallet.
Note: Be careful not to dislodge the black rubber vibration damper block in the
bottom front of the valve adjustment area (not on some R1100).
12. Remove the black rubber timing hole plug, located above and behind the
right side throttle body, using a long thin screwdriver to pry it off.
13.Turn the lower alternator pulley clockwise with a 16mm box wrench.
14. Insert a long screwdriver into the right side spark plug hole while turning the
engine over.
15. When the screwdriver is almost pushed out the maximum, use a flashlight
and start looking for the timing marks S – OT in the small timing window where
you removed the rubber plug. (some R1100 = Z – S – OT)
16. Center the OT mark in the window.
Note: Also at OT, the arrow on the cam chain gear will be pointing straight out.
17. Wiggle the valve rockers in and out on both sides - both the intake and
exhaust valve rockers for one side should wiggle slightly in and out, the rockers
on the other side should be tight.
18. You will be adjusting the valves on the side where they all wiggle slightly as
follows:
Valve Clearance
Intake = .006in. (.15mm)
Exhaust = .012in. (.30mm)
Valve Location
Intake Valves are to the rear (take air/gas in from the throttle body).
Exhaust Valves are to the front (exhaust to the exhaust pipes).
19. Adjust the proper valves, located as described above, using a 10mm box,
3mm hex T-handle, and feeler gauge(s) as given in the following steps.
Note: Each intake and exhaust has two valves each that are operated by a
forked rocker. Correct procedure calls for you to use two identical feeler gauges
simultaneously – one for gauging the valve you are adjusting, and the other as a
spacer on the other valve. This is to prevent the rocker from canting while you
are adjusting it. Many people get excellent results using only one feeler gauge
and skip the spacer feeler gauge.
20. Insert the correct feeler gauge between the valve stem and the adjuster
screw. There should be slightly firm drag on the feeler gauge – be sure that you
do not have the gauge canted or curved as you are measuring.
11
Note: One method is to insert the feeler gauge and tighten the adjuster until the
feeler gauge will not slide, then back off the adjuster a little until the feeler gauge
begins to slide.
Note: You can use the “go, no go” method – a .008in. gauge should not go into
the .006 intake; a .014 should not go into a .012 exhaust if adjusted properly. A
.007 gauge will go into the .006 intake and a .013 gauge will go into the .012
exhaust, but will give a too tight drag.
21. If any valve needs adjusting, loosen the adjuster lock nut with a 10mm box
wrench and turn the adjuster screw with a 3mm hex T-handle to get the correct
clearance – slightly firm drag on the feeler gauge.
22. Slide the box wrench over the shaft of the 3mm hex T-handle and hold the
adjuster screw with the 3mm hex T-handle while tightening the lock nut with the
10mm box wrench (6 ft.lb or 8 Nm)
Warning! It is very easy for beginning mechanics to strip low torque threads -
eg. 6 ft.lb. Use a short grip on 10mm and smaller wrenches. It is also very easy
to strip low torque threads with a torque wrench because many torque wrenches
are improperly calibrated. Also, with click type torque wrenches it is very easy to
not feel the click at low torque settings and then your torque wrench becomes a
large breaker bar and you end up stripping the threads.
23. After tightening, double-check the clearance.
24. Rotate the engine 360 degrees to the same OT mark by turning the lower
alternator pulley clockwise with a 17mm box wrench as in step 13.
25. Check the rockers on the other side for wiggle – they should all wiggle slightly
26. Now adjust the valves on this other side.
27. Clean the valve covers of any dirt or oil on its sealing edge.
28. Wipe the oil off the valve cover gasket to help ensure no oil leaks. Place it
onto the head so that the edge with 3 notches goes to the top. Be sure all the
notches are fit into the corresponding studs on the head.
29. Be certain the center donut gasket is in place on the valve cover!!!
30. Carefully replace the valve cover so as not to dislodge the center donut
gasket.
31. Evenly tighten the 6mm hex bolts until they bottom out - 6 ft.lb (8 Nm).
32. Replace the small black rubber timing hole plug.
Warning!: Be careful!!! It is fairly easy to push it all the way through. I use a sharp
awl and stab the plug in the center to hold it. I then place the plug so its right lip is
under the timing hole edge and then use a long thin screwdriver to push the left
lip into place.
33. Leave the black valve cover strips and the valve cover protectors off until you
are done with the spark plugs in the next procedure.
12
Spark Plugs
Tools Parts
T-handle hex –5mm, 6mm spark plugs
plug wire cap puller
sparkplug socket
short extension
ratchet
rag
hex socket - 6mm
small flashlight
spark plug gauge
torque wrench
anti-seize paste
1. The spark plugs were removed in steps 1 – 9 of the preceding valve
adjustment procedure. Be sure to read the Warning! following step 9 of the valve
adjustment procedure.
2. Replace plugs every 12K miles.
3. Visually inspect the spark plugs and check each for abnormalities – carbon or
oil deposits, burned or cracked electrodes, etc.
4. If installing new plugs (every 12K miles), check that they are still set at the
factory set gap of .031 in (0.8mm).
5. Very lightly coat the plug threads with anti-seize.
6. Install the plugs by hand using only the spark plug socket to avoid any
possibility of cross-threading them.
7. Torque the plugs to 15 ft.lb.(20 Nm).
8. Push the spark plug wire caps firmly onto the spark plugs.
9. Replace the black valve cover strips by putting the two rear tits into place at
the spark plug wire and then pushing the front in until it snaps into place.
10. Replace the valve cover protectors using the 5mm hex T-handle – start the
bottom center bolt first - short screw goes to the front.
11. Replace the alternator cover – try to get the oil line brackets lined up first and
start the top right bolt first since you may need to push the oil line bracket to get
the bolt started – same with the bottom right bolt.
13
Air Filter
Tools Parts
phillips screwdriver air filter
rag
compressed air
1. Remove the rear and then the front seats.
2. Unscrew the two phillips screws holding the air filter cover down (some bikes
have clips).
3. Pivot the cover up.
4. Remove the old filter and inspect it for damage or replace it with a new one.
5. Place a rag tightly over the air intake where the air filter sat and blow all the
dirt and dead bugs out of the filter housing and air horn.
6. Insert the air filter being careful to seat it properly.
7. If the cover hinges came unhooked from their holes, pivot the cover up as high
as it will go and hook the hinge tabs into their holes by pivoting the cover down.
8. Fasten the cover by tightening the two phillips screws (or clips).
Warning!: The air filter housing is a prime candidate for a mouse nest and the air
filter for use as nesting material. Especially after winter storage be sure to check
your air filter. Or screen off the air horn opening during storage so mice can’t get
in there in the first place.
14
Lube Side Stand and Center Stand
Tools Parts
wire none
grease gun
chain lube
1. Remove the debris from the small grease hole (not found on some R1100) at
the rear of the pivot point on the side stand using a small wire or carb or brake
cleaner if necessary.
2. Use a cone tip adapter on your grease gun to grease the side stand or use
chain lube.
Note: Some bikes may have zerk fittings.
3. Spray the center stand pivot bushings with chain lube.
Lube and Adjust Clutch Cable (some R1100)
Tools Parts
phillips screwdriver #10 grease
1. Adjust maximum slack at the clutch lever
2. At the rear of the transmission pry the clutch release arm to release the clutch
cable there
3. Lube both ends of the clutch cable with BMW #10 grease
4. Reattach the cable at the transmission
5. Using the knurled adjuster at the hand lever adjust to 12mm between it and
the knurled locknut
6. At the clutch release arm loosen the 13mm locknut using a 13mm deepwell
socket and swivel
7. Adjust the 10mm bolt to give 7mm freeplay at the hand clutch lever
8. Pull in the hand clutch lever while tightening the locknut at the rear clutch arm
15
Brake and Clutch Fluid
Tools Parts
phillips screwdriver brake fluid
towel
Note: Some R1100’s do not have a hydraulic clutch. See previous procedure.
Note: Brake fluid can ruin the bike’s paint, so cover the tank and any painted or
plastic parts with a towel if you are adding or changing fluid!!!
Front Brake Fluid Reservoir
1. Put the bike on the centerstand.
2. Turn the handlebar straight ahead so the reservoir on the right handlebar is
level.
3. Check the fluid level in the sight glass of the reservoir.
4. Add only DOT 4 brake fluid if the level is at or below the LOWER level mark.
Rear Brake Fluid Reservoir
1. Put the bike on the centerstand.
2. Check the fluid level in the rear reservoir that is located on the right side just
below the seat.
3. Add only DOT 4 brake fluid if the level is at or below the LOWER level mark.
Note: If either the front or rear is low on fluid, be sure to check the brake pads for
wear! As the pads wear, more fluid is taken into the system.
Clutch Fluid Reservoir
1. Same as Front Brake Fluid Reservoir above, but on the left handlebar.
Brake and Clutch Fluid Replacement – Bleeding the Brakes
Note: BMW calls for a fluid change annually. Good brakes are too important to
skip this relatively straightforward procedure.
Note: There are some devices that aid in bleeding the brakes as you replace the
fluid:
1. Mityvac is a small hand held vacuum pump that sucks the brake fluid
down and out through the bleeder nipple at each brake caliper. It is
available at most auto parts stores.
2. Speed Bleeder is a one way valve bleeder nipple that replaces your stock
bleeder nipples. It is available at www.speedbleeder.com
16
3. One Man Brake Bleeder is a one way valve that attaches to your stock
bleeder nipple via a hose. It is available at some auto parts stores.
4. A turkey baster is handy for removing the old fluid from the reservoir
before you add the fresh fluid. Once you use it for brake fluid, do not
return it to the kitchen.
Note: If bleeding by the standard method of pumping the lever, do not pull the
lever all the way to the handlebar or you will force the caliper piston too far out
and possibly ruin the seal. This applies to the clutch and rear brake as well.
Note: On the 1150 GS, BMW has a plug or grub screw instead of a bleeder
nipple on the right front brake caliper and on the clutch slave cylinder. BMW
wants you to replace these with a bleeder nipple to bleed the system and to then
reinstall the grub screw when you are finished.
Note: For brake bleeding procedures see page 42.
Brake Pads
Tools Parts
phillips screwdriver brake fluid
Note: Check front and rear pads for wear and replace them if they have less than
1 mm of pad left. Remove the right saddle bag so you can do a good inspection
of the rear pads. See the section on brake pad replacement.
Warning: Due to a sticky rear brake retaining pin, the rear pads can wear out in
only a few thousand miles. Clean the pin with fine emery paper and lube it with
anti-seize. See the section on brake pad replacement.
Note: If either the front or rear brake fluid reservoir is low on fluid, be sure to
check the brake pads for wear! As the pads wear, more fluid is taken into the
system.
Note: Be sure to check the brake fluid reservoir after replacing the pads as fluid
is forced back into the reservoir by the new thicker pads – the reservoir may be
too full.
17
Battery Inspection
Tools Parts
flashlight, minimag distilled H2O
phillips screwdriver
hex socket – 6mm
ratchet
Quick Check Method
1. Place the bike on the centerstand.
2. Remove the front seat.
3. Hold a minimag flashlight right up against the battery, at the expected
electrolyte level, and next to the cell you are checking.
Note: I have a 4 cell minimag type flashlight that is brighter and works somewhat
better than a minimag.
4. Gently rock the bike so that the battery electrolyte sloshes back and forth. It is
this movement of the electrolyte that you are able to see.
5. Repeat for the other cells.
6. If the electrolyte level is low, follow the Standard Method below.
7. Reinstall the front seat.
Standard Method
1. Remove the seats.
2. Remove the right side black plastic panel below the fuel tank.
3. Remove the fuel tank bolt, 6mm hex socket, right side of fuel tank – be careful
not to lose the nut on the inside and the bushing in between.
4. Slide the tank straight back as far as it will go.
5. Check the battery electrolyte level from in front of the tank.
6. Fill to the max level with distilled water only – use a squirt bottle with a small
hose attached.
7. Clean and grease the battery terminals.
8. Reinstall the fuel tank being sure the black rubber connectors at the front of
the tank are in place.
9. Buy a sealed maintenance free battery and skip steps 1 – 8.
10. Leave the tank off if you are doing a fuel filter change.
Warning: On bikes with Motronic 2.4 (1150), when you disconnect the battery or
the battery dies, settings that are stored in the Motronic 2.4 memory are lost.
After disconnecting the battery or removing the Motronic fuse (#5), switch on the
ignition and then fully twist the throttle all the way open once or twice. This will
restore the throttle valve settings to the Motronic memory. This does not apply to
Motronic 2.2.
18
Fuel Filter
Tools Parts
siphon fuel filter
empty gas can large tank o-ring
rubber gloves 2 small hose clamps
pencil 2 tiny hose clamps
hex bit socket – 6mm
socket – 8mm
ratchet
Note: The following is based on the procedure for my R1100R which should be
similar to other oilheads.
1. Ride the bike until you are almost out of gas or siphon the gas from the tank.
2. Remove the seats.
3. Remove the right side black plastic panel below fuel tank.
4. Remove the fuel tank bolt, 6mm hex bit socket, right side of fuel tank.
5. Set the tank to the side of the bike – lawn chair with an old blanket to prevent
scratching the tank.
6. With the tank on its side, remove the fuel pump plate, 8mm socket.
7. Disconnect the fuel overflow and vent hoses – the 2 small hoses inside the
tank, noting which hose goes where.
Warning! Do not get any of the hoses mixed up! Label them.
8. Remove the pump unit from the tank.
9. Replace the fuel filter noting the direction of flow.
10. Reconnect the new fuel filter using the 2 small hose clamps.
11. Insert a new o-ring into the tank groove.
Note: The original o-ring swells and will not fit unless you let it “dry” for a few
days.
12. Insert the pump unit into the tank.
13. Reconnect the 2 small hoses being sure to connect the striped hose to the
striped hose using the 2 tiny hose clamps.
14. Evenly tighten the fuel pump plate, 8mm socket.
15. Install the fuel tank.
16. Check for any leaks
19
Miscellaneous
Tools Parts
tire gauge none
sockets
hex bit sockets
ratchet
torque wrench
powdered graphite
T-40 Torx bit socket
1. Check tires for nails, tread wear, damage, etc.
2. Check tire pressure.
3. Check rear wheel lug bolts, 17mm socket, torque to 105 Nm.
4. Check the front wheel – axle bolt, 30 Nm, - axle clamp bolts, 22 Nm.
5. Check all nuts and bolts.
6. Check all lights.
7. Check horn.
8. Check all air and oil hose clamps.
9. Check the throttle cables.
10. Check for debris in the throttle cable pulleys.
11. Check rotor rivets.
12. Lube locks with powdered graphite.
13. Check the front wheel bearing.
14. Check the rear wheel bearing.
15. Check the swing arm bearings.
16. Check the spokes front and rear – tap them with a box wrench, if they are
properly tensioned they will “ping” at various pitches when tapped. If too loose,
you will hear more of a thud sound – tighten the spoke until it pings, T-40 Torx. It
is generally recommended that you do NOT try to true these wheels yourself,
only tighten the occasional loose spoke.
17. Splines – it is generally considered that the splines do not require lube
maintenance. If you find it necessary to do a spline lube see page 74 for a
detailed procedure.
20
Sump Guard Removal (GS only)
Tools Parts
socket – 10mm loctite(?)
ratchet
channel lock pliers
Note: Before you do the test ride, remove the sump guard (skid/bash plate) from
the bottom of the engine in preparation for the oil and filter change after your test
ride. It is much more pleasant to do before the engine is hot.
1. Remove the four nuts holding the sump guard on, using a 10mm socket and
ratchet
Note: If the rear (or front) studs come out with the nuts, loctite the studs into the
engine block after you remove the nuts. Once off, the nuts can be removed by
holding the rubber spacer with channel lock pliers. The rear nuts are self-locking
and will remove more easily after a few removals. (R1100GS may have the self-
locking nylock nuts front and rear).
2. Clean the stones, dirt, and dried mud from the sump guard plates.
Note: If you do not ride your GS offroad, you can consider leaving the sump
guard plates off permanently for easier oil changes.
Test Ride Bike
1. Take the bike out for a test ride, ~15 min., to get the bike to operating
temperature for the throttle body sync and fluid changes in the next several
procedures.
2. After the ride, check for oil leaks around the valve covers.
21
Hot Engine and Drivetrain Procedures
(i.e. normal operating temperature)
Throttle Body Sync
Tools Parts
Twin Max or carb stix none
screwdriver, flat blade
needle nose pliers
wrench, 10mm
house fans
Note: If you are doing this procedure for the first time, you should seat the brass
bypass screws and record the number of turns for each. Return the screws to
where you found them. Also make a note of the number of threads at some
reference point on the right throttle body cable adjuster. All this is so you can get
back to the same starting point if you mess up.
1. Engine hot at the normal operating temperature of 5 bars on the RID.
2. Bike on the centerstand, transmission in neutral.
Note: If you are experienced with this procedure, it only takes a couple of
minutes – including several double checks. If you have never done a throttle
body (TB) sync or your TB’s are really out of sync, it could take much longer and
you should place 1 or 2 house fans blowing on your engine to help keep it from
overheating.
Note: You may need to slacken the throttle body cables. See pages 53 - 59.
3. Turn on the Twin Max to warm up it up to help prevent drifting from the zero
calibration setting.
4. Remove the vacuum hoses from the bottom of each throttle body (TB).
5. Attach the Twin Max hoses to each TB, left hose to the left TB, right hose to
the right TB.
6. Calibrate the Twin Max by setting the sensitivity to max and then zero the
needle.
Idle Speed Adjustment and Balance
7. Start the engine.
8. Turn the Twin Max sensitivity down if the needle is fluctuating too much, but
get it back to or close to maximum sensitivity as you do the final adjustments.
9. Adjust the large brass bypass screw on each TB to get an idle speed of
~1100rpm - turn both out, counterclockwise, to increase the idle speed
22
- turn both in, clockwise, to decrease the idle speed.
10. Adjust the same large brass bypass screw on each TB to get the Twin Max to
zero i.e. to balance the TB’s at idle. You can turn just one of the screws for a
minor adjustment, or both screws in opposite directions if the balance if off quite
a bit. The screws should be within ~1/2 turn of each other when you are finished.
11. Shut the engine off and recheck that the Twin Max is still calibrated to zero.
12. Start the engine and double check the idle speed adjustment and balance.
“High” Speed Balance
Note: It used to be recommended to do this adjustment at ~3000 - 4000 rpm or
normal cruising rpm where surging would be most noticeable. However, Paul
Glaves points out that an adjustment at just off idle will be more accurate
because any difference between the throttle plates, left to right, will be a higher
percentage difference in the airflow and vacuum.
12. With the grip throttle, raise the rpm’s to just off idle, ~1500 rpm.
13. The Twin Max needle should remain at zero, if not you will need to adjust the
right side throttle body cable.
14. Loosen the right TB cable locknut, located just to the left of the right TB,
using a 10mm wrench.
15. To get zero at off idle, turn the adjuster on the above cable as follows:
clockwise – moves the Twin Max needle left
counterclockwise – moves the Twin Max needle right
Note: Since the adjustment usually changes when you retighten the locknut, it
may be easiest to turn the adjuster a little in the correct direction eg. 1/8 turn, and
then tighten the locknut with the 10mm wrench while holding the adjuster with
needle nose pliers. Now look at the Twin Max to check your adjustment at off
idle. Keep repeating small changes of the adjuster and tightening the lock nut
until you have zero at off idle.
16. Turn the engine off and recheck that the Twin Max is still at the zero
calibration.
17. Start the engine and do a quick double check of the idle speed adjustment
and the off idle (high) speed adjustment.
18. Turn the engine off and remove the Twin Max hoses from the TB’s.
19. Reconnect the vacuum hoses to the TB’s.
Note: For more detailed instructions see pages 53 - 59.
23
Engine Oil and Filter Change
Tools Parts
oil filter tool oil – 4 qts.
hex bit socket – 8mm oil filter
ratchet crush washer - drain plug
torque wrench
rubber gloves
funnel
oil drain pan
rag
1. Remove the sump plates (skid/bash plates) – see page 18 for instructions.
2. Be sure the engine is hot (go for a short ride).
3. Place the oil drain pan under drain plug (bottom right side of engine).
4. Wear rubber gloves - oil is carcinogenic, plus when you accidentally touch the
hot headers!!! or get hot oil!!! on your hands it won’t hurt as much.
5. Remove the oil drain plug located to the right of the oil filter, 8mm hex bit
socket.
6. Remove the oil filter, oil filter tool and ratchet.
7. Remove the oil filler cap to help draining.
8. Let drain for ~10 min.
9. Use the rag to remove any dirt from around the drain plug area and from the
oil filter well.
10. Install the drain plug with a new crush washer and torque to 23 ft.lb. (32 Nm).
11. Fill the new oil filter with fresh oil.
12. Apply a thin coat of oil to the new oil filter rubber gasket.
13. Install the new oil filter and give it ¾ - 1 turn after first contact.
14. Add 3.75 – 3.9 qts. of oil total (NOT 4 qts.!!!) using a funnel or oil spout.
15. Install the oil filler cap.
16. Run engine at idle for 2 – 3 min.
17. Wait ~10 min. and check to be sure the oil level is at the dot in the center of
the sight glass.
18. Check for any oil leaks at filter and drain plug.
Note: You may get more consistent oil level readings if you put the bike on the
sidestand for a few minutes and then put it on the centerstand.
24
Transmission Gear Oil Change
Tools Parts
hex bit socket – 8mm gear oil, synthetic (75W/90) 1000cc
socket – 13mm crush washers
ratchet - drain plug
short extension - fill plug
oil drain pan
carb or brake cleaner
torque wrench
clear tubing (tygon)
funnel
measuring cylinder (photo store)
rag
1. Put the bike on the centerstand.
2. Place the oil drain pan under the drain plug.
3. Remove the drain plug on the right side of the transmission just above the
brake pedal, 8mm hex bit socket. (some R1100 transmission drain plugs are just
below the fill plug, hidden up the “tunnel”, 13mm socket).
4. Remove the fill plug on the right side of the transmission just above the drain
plug, 8mm hex bit socket.
5. Clean the metal filings from the magnetic drain plug using a rag and carb or
brake cleaner.
6. Install the drain plug using a new crush washer, torque to 22 ft.lb. (30 Nm).
(Some R1100’s do not use a crush washer on the transmission drain plug).
(Some R1100’s torque the drain plug to 17 ft.lb. (23 Nm)).
7. Fill the transmission with 1000cc (1.06 qt.) of synthetic gear oil using the
flexible tubing and a funnel – fill to the bottom edge of the filler hole. (Some
R1100’s specify 800cc – check your owners manual)
Note: I use tygon tubing from the hardware store – one end goes into the fill hole
and a funnel is inserted into the other end.
8. Install the fill plug using a new crush washer, torque to 22 ft.lb. (30 Nm)
(Some R1100’s torque the fill plug to 17 ft.lb. (23 Nm)).
25
Rear Wheel Drive Gear Oil Change
Tools Parts
socket – 19mm gear oil, synthetic (75W/90) 250cc
hex bit socket – 6mm crush washers
ratchet - drain plug
oil drain pan - fill plug
carb or brake cleaner
torque wrench
funnel
measuring cylinder (photo store)
rag
1. Put the bike on the centerstand.
2. Remove the right saddle bag.
3. Place the oil drain pan under the drain plug.
4. Remove the drain plug on the bottom center of the rear wheel hub, 19mm
socket.
5. Remove the fill plug at the rear of hub, 6mm hex bit socket.
6. Clean the metal filings from the magnetic drain plug using a rag and carb or
brake cleaner.
7. Install the drain plug using a new crush washer, torque to 17 ft.lb. (23 Nm).
8. Fill the rear wheel drive with 250cc (0.26 qt.) of synthetic gear oil using a
funnel – fill to the bottom inside edge of the filler hole threads.
9. Install the fill plug using a new crush washer, torque to 17 ft.lb. (23 Nm).
Sump Guard Installation (GS only)
Tools Parts
socket – 10mm none
ratchet
1. Reinstall the sump guard (skid/bash plates), 10mm socket.
Note: The front nuts with their metal sleeve will tighten up normally. However, the
rear nylock nuts will not get tight because of the rubber spacers above the plates
– so just tighten them until they are snug. (R1100GS may have the self-locking
nylock nuts front and rear).
26
Other Procedures
Brake Pad Replacement
Tools Parts
hex bit socket – 8mm brake pads
ratchet
hammer
punch (nail?)
screwdriver, flat blade
torque wrench
Note: I have not done this procedure on an R1150GS yet, so the following is
based on the procedure for my R1100R which should be similar.
Note: Many riders are particularly pleased with EBC pads which can be ordered
through any motorcycle dealer from Tucker-Rocky.
Front Pads (2 sets) - - - - - all R1100’s = EBC # FA246
Rear Pads - - - - - - - - - - - - GS, R, RT = EBC # FA245
- - - - - - - - - - - - - - - - - -RS = EBC # FA171
The EBC pads may not be a perfect fit. The front pads may need very gentle
filing where they touch in the top inside corners (see where the paint is worn off
on the OEM pads). The top rear corner of the rear outside pad needs some
grinding or filing so that it fits - hold the EBC pad back to back with the opposite
OEM pad (inside pad) to see where and how much of the backing plate to
remove. This may sound like a hassle but it is quite easy to do.
Note: Anti-rattle springs - Some riders remove the anti-rattle springs from the
original OEM pads by drilling them out and then riveting them to the new EBC
pads which do not come with springs.
Note: Several riders on the GS list have reported that they are pleased with the
Galfer pads and the EBC HH pads.
Note: Be sure that your front brake reservoir is not over full - less than max! You
do not want to force brake fluid out the reservoir when installing the new pads!
Cover your fuel tank as a safety measure to prevent accidental overflow of brake
fluid from eating your paint!!!
Note: Pay special attention to the rear outside pad when inspecting for wear as
many riders are wearing this pad out as early as 6K miles!
27
Front
1. Place the bike on the centerstand.
2. Remove the front caliper bolts that hold it to the fork leg, 8 mm hex bit socket
3. To remove the caliper, gently rock it back and forth on the rotor to spread the
brake pads.
Warning! Do NOT compress the front brake lever while the calipers are removed!
4. Remove the keeper from top of the caliper with pliers.
5. Drive out the pin from wheel side with a hammer and punch
6. Remove the old pads.
7. Push the wheel cylinders in all the way with your thumbs.
8. Insert new pads (no anti-rattle spring on EBC pads).
9. Drive in the pin, turning it with a screwdriver so the keeper hole is on top.
10. Insert the keeper
11. Spread the pads again if necessary.
12. Install the caliper onto the rotor.
13. Install the caliper bolts, torque to 30 ft.lb. (40 Nm).
14. Pump the front brake lever until pressure returns!!!!!
15. Repeat for the other front caliper.
16. Pump the front brake lever until pressure returns!!!!!
17. Check the brake fluid level in the front reservoir.
Rear
Warning: Due to a sticky rear brake retaining pin, the rear pads can wear out in
only a few thousand miles.
1. Place the bike on the centerstand.
2. Remove the saddlebags.
3. Remove the keeper from the pin.
4. Drive out the pin from the keeper side (drive toward the wheel).
5. Remove the caliper bolts that hold it to the rear drive, 8 mm hex bit socket.
6. To remove the caliper, gently rock it back and forth on the rotor to spread the
brake pads.
Warning! Do NOT compress the rear brake pedal while the calipers are removed!
7. Remove the old pads.
8. Grind or file the EBC pads to fit (see note above).
9. Insert new pads.
10. Clean the pin with fine emery paper and lube it with anti-seize.
11. Drive the pin in.
12. Insert the keeper.
13. Install the caliper onto the rotor.
14. Install the caliper bolts, torque to 30 ft.lb. (40 Nm).
15. Pump the rear brake pedal until pressure returns!!!!!
16. Check the brake fluid level in the rear reservoir.
28
Tire Change
Tools Parts
hex bit socket –6, 8mm tires
ratchet wheel weights
socket – 17mm
screwdriver
pencil
wood frame of 2x2” (16” sq. OD)
bead breaker (JC Whitney)
balancing stand (homemade)
tire irons, 3
tire lube
paint brush (for applying lube)
valve core tool
heavy rubber mallet
razor knife
dish soap
compressed air supply
alcohol
rag
torque wrench
short extension
rear wheel axle adapter (BMW)
axle to fit adapter (BMW)
tape
grease
Front Wheel Removal
1. Place the bike on the centerstand.
2. Weight the rear of the bike so it will not rock forward.
3. Remove both sets of calipers, 8mm hex bit socket to remove the 2 bolts
holding each caliper to the bottom of the fork leg
4. To remove the caliper, gently rock it back and forth on the rotor to spread the
brake pads.
Warning! Do NOT compress the front brake lever while the calipers are removed!
5. Remove the axle “nut” (bolt) from the left end of the axle, 17mm socket
6. Loosen the axle clamp bolts several turns, 6mm hex bit socket.
7. Note carefully the orientation of the speedometer drive unit so you get it
installed correctly later on!!!
8. Insert a screwdriver into the end of the axle and pull and twist to remove the
axle while supporting the tire (watch for the spacer on the right side).
9. Roll the wheel out.
10. Now is a good time to take a good look at the brake pads.
11. Check the front wheel bearing.
29
Front Tire Change
Hints: Warm the tires in the sun! A warm tire goes on much more easily.
When levering the last of the tire bead onto the wheel, be absolutely certain the
opposite bead is not seated but rather squeezed into the middle of the wheel.
Put just the wheel, no tire on it, on the balancing stand and check for the heavy
spot and use that rather than the tire stem for the heaviest spot.
Tire Removal
1. Place the wheel on the wooden support frame to prevent rotor damage (or
remove the rotors, 5mm hex bit socket).
2. Mark the direction of rotation on the wheel so you don’t put the new tire on
backwards!
3. Remove the valve core with the valve core tool being careful not to let it get
launched.
4. With the wheel in the wooden frame, break the bead all around on both sides
with the bead breaker being careful that it does not slide into the wheel and
scratch it
5. Lube the bead on one side with tire lube.
6. Pry off the first side with 2 or 3 tire irons (tape them with electrical tape or duct
tape to avoid scratching the wheel).
Note: The GS has very thick rim edges and regular rim protectors do not fit. Also
because of the thick rim edges, tire irons tend to slip off unless you insert them a
little farther than usual.
Note: There is a bit of a trick to getting the second side off. Proceed as follows:
7. Lube both sides of the second bead extra well – this is the hard one to
remove.
7. Stand the tire and wheel vertical
8. With 1 or 2 tire irons reach into the wheel and pry the second side over the
edge of the wheel (pry it part way off) and hold it there under tension.
9. Take the heavy rubber mallet and pound the tire off the rest of the way.
10. Clean the wheel of any dirt. Clean off any old rubber from the wheel where
the tire seals.
11. Remove the old wheel weights with a razor knife and alcohol.
12. Balance just the wheel to confirm (or not) that the valve stem is the heaviest
spot. Mark the heavy spot if different than the valve stem.
Tire Installation
13. Align the painted tire balance dot with the tire stem or heavy spot on the
wheel!!! and the correct direction of rotation!!!
14. Lube the first bead of the new tire and push it on with hands, knees, feet and
tire iron.
30
15. Lube the second bead and push it down with hands, knees, feet ~ ¾ the way
on.
16. Using three tire irons pry the tire on the rest of the way - the real secret is to
be sure the opposite side of the tire is squeezed into the center of the wheel (use
bead breaker if necessary).
17. Double check alignment of tire balance dots with the valve stem!!!
18. Double check the direction of rotation.
19. Insert the valve core, inflate to seat tire, inflate to 40 psi – you should hear a
loud pop as each side seats.
20. Mix up some soap bubbles and check the bead/wheel seal on both sides and
check the valve core for leaks.
21. Check that the thin tire ridge is evenly spaced all the way around the wheel.
Front Tire Balance
1. Insert the axle into the wheel and place on the balancing stand.
2. Determine balance by taping assorted weights to the wheel.
3. Precurve the whole weight ribbon to same curvature as the wheel.
4. Clean the wheel with alcohol before sticking the weight on.
Front Wheel Installation
1. (Reinstall the rotors if you removed them, 24 Nm plus Loctite 243).
2. Grease the axle lightly.
3. Roll the wheel in – geared ABS teeth to the left side of the bike.
4. Lift the wheel slightly and start the axle from the right side of the bike and
insert the right side spacer and the left side speedo drive - the tab on top of the
speedo drive goes in front of the tab on the inside of the left fork leg.
5. Tighten the axle nut (bolt),17mm socket, torque to 22 ft.lb.(30 Nm).
6. Gently pry the brake pads apart with a tire iron.
7. Install the calipers, 8mm hex bit socket, torque to 30 ft.lb (40 Nm).
8. Pump the front brake lever until pressure returns!!!!!
9. With the bike off the centerstand compress the front forks several times with
the rear brake applied.
10. With the bike on the sidestand tighten the axle clamp bolts, 6mm hex bit
socket, torque to 16 ft.lb (22 Nm).
11. Pump the front brakes!!!
31
Rear Wheel Removal
1. Place the bike on the centerstand.
2. Block up the bike under the catalytic converter so the rear tire is up off the floor
3. Put the bike into first gear.
4. Remove both saddlebags.
5. Remove the rear brake caliper by removing the caliper bolts that hold it to the
rear drive, 8 mm hex bit socket.
6. To remove the caliper, gently rock it back and forth on the rotor to spread the
brake pads.
Warning! Do NOT compress the rear brake pedal while the calipers are removed!
7. Remove the 4 wheel lug bolts and cone spacers, 17mm socket.
8. Roll the wheel out.
9. Check the rear brake pads.
Rear Tire Change
1. Same as the front.
Note: The rotor is recessed from the outside of the rim and should be OK without
using the wooden frame, but be careful.
Rear Tire Balance
1. Same as the front EXCEPT:
a. Pry or push out the plastic hub cap in the center of the wheel.
b. The rear tire can be a real bear to get on – helps to have a long 18” tire iron.
c. To balance, attach the four hole axle adapter to the rear wheel using the lug
bolts and spacer cones.
d. Reinstall the little plastic hubcap.
Rear Wheel Installation
1. Gently pry the brake pads apart with a tire iron.
2. Roll the wheel into place.
3.Install the 4 lug bolts and cone spacers, 17mm socket, FIRST torque to 37 ft.lb.
(50 Nm) THEN final torque to 77 ft.lb. (105 Nm).
4. Install the caliper, 8mm hex bit socket, bolt + lockwasher goes to the rear, bolt
only goes through the ABS wire bracket, torque to 30 ft.lb (40 Nm).
5. Pump the rear brake pedal until pressure returns!!!!!
32
R1100 Routine Service – Paul Glaves
In this article we will cover the specifications and other information needed for a
mechanically experienced R1100 owner to perform routine maintenance on his or her
motorcycle. This article is not intended to teach the mechanically inexperienced owner
everything they need to know about maintaining an R1100 motorcycle. From my
experience, at least 90% of motorcycle maintenance is core knowledge of fundamental
mechanic’s technique. Ten percent is motorcycle model specific. We’ll cover some of
that fundamental 90%, but will mostly cover the specifications and procedures which
specifically apply to the R1100. Please be careful. Maintenance of a high speed motor
vehicle is serious business. Your valuable machine and your personal safety depend on
your abilities. If you break something or ruin something it won’t be BMW’s fault. It won’t
be my fault. You are responsible for what you do and how you do it. Be careful!
BMW has used different terminology to describe maintenance intervals and
requirements over the years. Back in the old days we did “5,000 mile services” and
“10,000 miles services.” At times we referred to “major services and minor services”. At
other times the terms “Service I” and “Service II” have been used as have the terms
“BMW Service” and “BMW Inspection” The R1100 Repair Manual uses the following
terminology:
Inspection I = 1000km (600 mile) Service
Inspection II = BMW Upkeep Service (equivalent to Service I or Minor Service)
Inspection III = BMW Inspection (equivalent to Service II or Major Service)
Inspection IV = Annual Service (to be performed at least once each year regardless of
mileage)
The specified mileage intervals for Inspection II’s and Inspection III’s are in the technical
information in the book(s) supplied with your R1100 motorcycle. All of those I have
personally examined call for an Inspection II at 6,000 miles (10,000km) and each 12,000
miles thereafter. An Inspection III is called for at 12,000 miles (20,000km) and each
12,000 miles thereafter. These requirements translate as follows:
600 Miles - Initial service
6,000 Miles - Inspection II (Minor Service)
12,000 Miles - Inspection III (Major Service)
18,000 Miles - Inspection II (Minor Service)
24,000 Miles - Inspection III (Major Service)
Continuing - alternating major and minor services each 6,000 miles)
There may be variations or changes, so check the book that came with your motorcycle.
For simplicity and clarity for the balance of this article, I am going to use the terminology
Minor Service and Major Service to describe the specified maintenance items.
Before going further, a word about the warranty and maintenance requirements. BMW
provides a limited warranty which warrants the motorcycle against defects in materials or
workmanship in the manufacture of the motorcycle. BMW expects that your motorcycle
will receive the specified maintenance at the specified interval. BMW does not require
that this maintenance be performed by certified mechanics at a franchised dealer.
However, in the event of a malfunction or failure, determining whether or not the failure
represents a defect in materials or workmanship in the manufacture of the motorcycle or
33
represents a failure due to a lack of maintenance or improper maintenance may be an
issue. Do not take shortcuts! Do not neglect recommended maintenance! Document
the maintenance you do!
I do not recommend that any owner perform the initial (600 mile) service on a
motorcycle. More than maintenance is involved at this step. This is the dealer’s
opportunity to fully inspect the motorcycle after its initial use to detect anything which
appears abnormal or defective in assembly or adjustment. Even experienced
owner/mechanics usually lack the specific knowledge about their new bike to reliably
perform this inspection. I do practice what I preach. Engle Motors in Kansas City has
always done the initial service on our new bikes.
Lets look at the R1100 service requirements. This information is drawn primarily from
the R1100RS/GS Repair Manual. There may be additional minor items specified for the
R/RT models. Consult your dealer.
MINOR SERVICE:
Oil and Oil Filter: Drain the oil warm. Allow the engine plenty of time to drain. The oil
is slow to drain down (and out). Find the oil filter - recessed at the left front bottom of the
engine case. Remove the oil filter with the special oil filter wrench. Be careful not to
allow spilled oil to burn your hand or arm. Fill the new filter with oil. Keep track of the
amount of oil poured into the filter. Lightly oil the filter gasket. Tighten the filter finger
tight and then 1/4 turn additional rotation. Add new oil to the engine. I add 3.5 quarts
including the oil poured into the new filter. After a few minutes it may require one or two
additional ounces of oil. Fill to the dot on the sight glass. Filling above the dot on the
site glass appears to increase oil consumption and is not recommended.
Adjust Valves: The specifications for the valve adjustment are .006 inch (.15mm)
intakes and .012 inch (.30mm) exhausts. Each cylinder has two of each type valve.
Remove the front cover. Remove the spark plug connector. Use compressed air to
blow the bugs and rocks out of the spark plug recess. Remove the valve covers. Set
the engine to top dead center by centering the “OT” timing mark visible in the timing port
on the right side of the engine. You will, of course, need to remove the rubber plug from
the timing port in the side of the block. Find the cylinder with free-play in both valves at
TDC. The rocker arms are forked to actuate both valves with a single pushrod. For
precise adjustment, you should use two feeler gauges at the same time to eliminate any
error from slight rocker arm tilt along the shaft. Loosen the locknuts and adjust the gap
using a small allen wrench in the screw adjuster. Adjust so that there is light drag on the
feeler gauge at the specified gap, and so that the next larger sized feeler gauge will not
insert into the gap. For example, adjust each intake valve so there is light drag on the
.006” feeler gauge and so that the .007” feeler will not insert into the gap. Rotate the
engine exactly 360 degrees to TDC again. Adjust the valves for the other cylinder.
Before refitting the valve covers, remove and thoroughly clean all the oil off the gaskets
and their mating surfaces. Installing oily gaskets will cause oil to continue to weep past
the gaskets.
34
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 the connections for signs of corrosion. Clean the terminals and connections as
required.
Check and Adjust the Alternator Drive Poly Belt: The alternator drive belt is located
behind the front cover. The alternator is mounted so that it can slide vertically up or
down when the retaining bolts are loosened. The lower retaining bolt on the left side
(your right as you are facing the front of the engine) contains a geared adjuster. The
adjustment specifications call for loosening the retaining bolts. Then tighten the geared
adjuster using a torque wrench to 70 inch lbs = 5.9 foot pounds = 8 newton meters. This
rotation raises the alternator and this properly tensions the belt. Tighten the other
retaining bolts to hold the alternator in place with the proper belt tension. To check the
tension of the belt without disturbing it, grasp one side of the belt midway between the
pulleys and twist it 90 degrees. If it will twist much over 90 degrees it is too loose. If you
cannot cause it to twist 90 degrees it is too tight. If the belt is too tight it places undue
stress on the alternator bearings. If it is too loose it will squeal. Please note that the
belts now in use by BMW will slightly squeal for a few seconds when the engine is
started cold. This is normal. Do not attempt to make the belt so tight as to eliminate this
cold start-up squeal. It will then be too tight.
Check the Spark Plugs: The spark plugs should be visually examined each Minor
Service. You should not expect to need to replace them at this interval however. The
early R1100’s used spark plugs with three side electrodes. The current specification is
for spark plugs with two side electrodes. Examine the electrodes for signs of wear and
examine the insulator color. You are looking to find a very light tan insulator. A bright
white with blisters would indicate a lean mixture or other cause of overheating. Consult
any good motorcycle or car repair manual for the color spark plug pictures which show a
number of fuel fouled, oil fouled, lead fouled, and other abnormal conditions. Apply a
light coating of anti-seize to the threads when installing the spark plugs. Be careful not
to get any anti-seize on either the electrodes or the insulator. The torque specification
for the spark plugs is 15 ft. lbs (20nm).
Check the Brake Pads: Remove the brake caliper covers (lightly spread the cover
using a small pry bar or screw driver and lift upward). Carefully examine the brake pads
for wear. Do NOT assume since you brake properly as taught by the MSF and mostly
use your front brakes - that the rear pads do not need to be checked. The R1100
motorcycles consume rear brake pads at a relatively short interval. Examine them each
service, and expect to need to replace them every 20,000 to 30,000 miles. I know of
cases where the pad was gone and the backing plate scored the disk in 12,000 miles.
I’ve also seen them last 35,000 miles, but not a lot more. Even with proper braking
technique the front pads are likely to outlast the rear pads 2 to 1. The minimum lining
thickness is specified as 1.5mm (.06”)
35
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 rear rotor. Carefully examine the “rivets” which attach the front floating
disks to their carriers. These wear, and need to be replaced when worn. Each rotor is
mounted with two types - which may be identified as having a large hole or smaller hole
in the center of the “rivet.” Each thicker rivet with a small hole is located between groups
of 3 of the thinner walled rivets with the larger holes. They affix with a small flat spring
washer and a circlip located on the inside (wheel side) of the disk.
Grease the Side Stand and Center Stand: Grease the side stand and center stand
(some models only). There is not much else to say about this service. Check that the
center stand bolts are tight. The torque specification is 15 foot pounds. (21 nm)
Adjust the Clutch: Adjust the cable adjuster located at the handlebar end of the cable
so that the distance (exposed threads) between the adjuster and the locking ring is
12mm (.47”). Then, at the rear of the transmission loosen the 13mm locknut and adjust
the 10mm adjusting bolt so that the freeplay distance measured between the handlebar
lever and its housing is 7mm (.28”). Freeplay is the distance the lever moves taking up
the slack in the adjustment prior to actually beginning to disengage the clutch. Then pull
the clutch lever in so that there is pressure on the 10mm bolt to hold it from turning, and
tighten the 13mm locknut - just snug but not gorilla tight. I have seen cases where the
locknut and adjusting bolt have loosened, so some blue Loctite 242 is appropriate at this
location. Lubricate the clutch cable ends by applying grease where the barrels on the
ends of the cables contact the clutch levers.
Synchronize the Throttle Bodies: Adjust the choke cable so there is approximately
1mm (.04”) of free play in the cable. Rotate the handlebars fully to the right and adjust
the cable from the twistgrip to the left throttle body so that there is approximately .5mm
(.02”) of free play in the cable. Using a mercury manometer (Carb Stix or equivalent)
adjust the adjuster at the right throttle body to synchronize it to the left throttle body with
the twist grip rotated so the engine is operating just above idle with no slack in the
cables. Adjust the idle speed and balance the throttle bodies at idle by rotating the brass
recirculating air screws on the upper rear of each throttle body. For more detailed
instructions see the synchronization instructions in the article entitle Zero=Zero by Rob
Lentini. If you have the new twin cable equipped engine, then synchronize by adjusting
the freeplay on both cables equally to approximately 1mm.
Lubricate the Lower Front Shock Mount: Remove the lower front shock mounting
bolt and the two black spacers which are located between the sides of the shock “eye”
and the mounting bracket on the Telelever arm. Clean the bolt, the spacers, and the
shock mount. Grease the shank of the bolt and apply a light smear of grease on both
sides of each spacer. Reassemble and tighten the bolt. The torque specification is 43
nm (32 ft. lbs) for the early RS’s and 50nm (37 ft. lbs.) for the later RS’s, GS,s and RT’s.
Note - if your R1100 makes a strange clicking sound from the front end, it is likely that
the lower shock mount needs to be greased.
36
MAJOR SERVICE:
For a Major Service, perform all of the service items called for in a minor service, and in
addition 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 the right side of the
transmission. The drain plug is not in the bottom of the transmission, where it would
dump oil onto the catalytic converter and exhaust system. It is located beneath the fill
plug on the right side of the transmission, recessed into the “tunnel” cast into the lower
right side of the transmission case. BMW specifies 80, 90, or 80w90 wt gear oil.
Consult your manual for the temperature ranges. Fill the transmission to the bottom of
the fill hole threads. This is a specified quantity of 800cc. Use new sealing washers on
the drain and fill plugs.
Change the Final Drive Oil: With the bike fully warmed up, drain the final drive oil and
refill the final drive. Use the same gear oil as for the transmission. Fill the final drive to
the bottom of the fill hole threads. This is a specified quantity of 230cc. Use new
sealing washers on the drain and fill plugs.
Renew the Air Filter.
Renew the Fuel Filter: The fuel filter is located inside the fuel tank. As an aside - when
I first serviced my K bike, I concluded that the fuel filter was installed in the most
obnoxious manner possible. I had to remove the entire gas tank filler cap and remove
and replace the filter located in the bottom of the tank. When I first serviced an R1100, I
discovered that BMW had devised an even more obnoxious location for the fuel filter.
Locate and identify the two fuel hoses and two vent hoses beneath the right side of the
fuel tank. Pull the two vent hoses loose at the inline connector. Clamp-off (I use small
vice grips) both rubber fuel lines forward of where they attach to the hard black lines to
which they connect. Remove the fuel lines where they connect and remove the tank.
Drain the tank. Locate the metal plate affixed to the side of the tank in the tunnel where
the tank straddles the engine. Remove the capscrews which attach the plate and fuel
pump assembly to the tank. Retract the plate about one inch from the tank and loosen
the two vent hoses connected to the inside of the plate, inside the tank. Carefully
withdraw the fuel pump assembly - with the filter, fuel pump, and fuel level float arm -
from the tank. It will seem like you are trying to extract about 7 inches of parts through a
5 inch hole - but by carefully positioning the float arm it will all come out without bending
or breaking anything, and without force.
Remove the old fuel filter and install the new filter. To reinstall the plate you will need to
use a new (large) sealing “O” ring for the plate. You will want to replace the crimp-on
clamps on the two vent hoses with two very small screw-type or spring-type hose
clamps. WARNING: These two vent hoses are submerged in gasoline inside the fuel
tank. If the hose connections inside the tank leak, then fuel will leak out through the vent
hoses. If this happens, you will be privileged to again remove the fuel tank and the fuel
pump assembly to renew the clamps and stop the leak.
37
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 at least once each year, regardless of mileage. BMW specifies that when
changing brake fluid or flushing the system the front (but not the rear) caliper pistons
need to be recessed fully back into their bores. This is so fluid is forced out of the
caliper cylinders and stale fluid is not trapped in the calipers. BMW specifies a special
tool to retract the pistons. If you are careful not to damage the pads, you can retract the
pistons with tapered wedges which should be left in place during the flushing operation
to hold the pistons in the retracted position. Despite the fact that there are bleed nipples
on the ABS system under the fuel tank, my Repair Manual only calls for bleeding the
entire system at the wheel caliper bleed nipples.
Renew the Spark Plugs: The spark plugs should be replaced at the Major Service
interval.
OTHER COMMENTS:
During both a major or minor service you should take the opportunity to thoroughly
inspect your motorcycle. When you have the fuel tank removed, for example, is an
excellent opportunity to examine electrical connections for signs of corrosion or wear,
and to examine other parts and pieces hidden beneath the tank or behind the body work.
Look for loose or worn fasteners. Get to know exactly what the various components are
supposed to look like. Be systematic. Use good tools. Allow plenty of time - several
hours at least - and go slowly and carefully. Do not get in “over your head” and if you
do, consult your dealer or some other person experienced with R1100 maintenance.
38
Valve Adjustment - Stephen Karlan (Dali Meeow)
TOOLS NEEDED
newspaper (oil catcher) flashlight drain pan
med. screwdriver (pry) 3, 4, 5, 6 mm T handle Allen plug tool
compressed air torque wrench 2 sets gauges
hemostat for rubber plug 10mm box wrench carb stix
5/8-in. or 17mm socket pliers
You must start with a cold engine. Put newspaper or drain pan under the cylinder heads
to catch the oil drips. Remove alternator cover using 4mm Allen wrench. Check
alternator belt for cracks and tension and then leave cover off for valve adjustment.
Remove round black rubber timing hole plug (size of quarter) located on right side of
engine (above and to the rear of the cylinder head) by grabbing the edge of the plug
with a hemostat (medical tweezers, marijuana roach holder) and pulling or carefully pry it
out with a long screwdriver. Timing marks will be seen inside of this hole later on during
the adjustment procedure.
Remove black plastic strip ("4 Valve" imprinted on part) covering the spark plug by hand.
Remove plug wire from plug by using 2-inch long black plastic loop tool contained in
your BMW tool kit. The purpose of the black plastic loop tool is to give you a handle to
pull on that will pull the plug wire off the plug. Holding onto the loop end, point open side
toward rear of bike while hooking the tool onto the plug wire boot, then pull out to
remove the plug wire. Use compressed air to blow out plug hole before removing plug --
there will be dirt in that hole that you don't want in your cylinder !! At the very least, use a
tube or straw to direct the air and lots of lung force. Remove spark plug using tool kit
wrench. Place a pan/newspaper under the valve cover to catch the small amount of oil
that will drip out when you loosen the four valve cover Allen screws. Loosen the Allen
screws with a 6mm wrench and remove the valve cover; lightly tap if it's stuck.
With bike on centerstand and in neutral, use appropriate socket (5/8-in. or 17mm,
depending on bike) to turn the lower alternator drive pulley (and engine) clockwise.
Insert long screwdriver into either spark plug hole while turning engine over; when
screwdriver is being pushed out, start looking for timing marks. Use a small flashlight to
illuminate the flywheel marks. The marks, in order, are "Z", "S" and "OT". Center "OT"
in the timing hole opening.
Optional method #1 for moving the cylinders into place: Instead of looking at the
flywheel index marks, remove both spark plugs and put the bike on the center stand in
5th gear. Put a long screwdriver into either spark plug hole and push it against the
piston crown. Rotate the rear wheel until the screwdriver projects the maximum distance
out of the cylinder. Rock the engine by moving the rear wheel slightly back and forth to
get the piston at the very top, OT.
With OT centered, the valves on one side of the engine will "wiggle" a little bit. If they do
not "wiggle", check the valves on the opposite side of the engine. One side or the other
must wiggle. Adjust valves using 10 mm box wrench, 3mm Allen and two feeler gauges.
BMW recommends the following two feeler gauge dance step. One gauge is used to
adjust the intake (or exhaust) valve while the second feeler gauge is positioned under
the adjoining intake (or exhaust) valve to stabilize and prevent the rocker from canting.
39
After the first valve is adjusted, the second valve will then be adjusted while the first is
stabilized. To check if a valve is properly adjusted, attempt to insert the next thicker size
of feeler gauge -- it should be too big to fit. The valve clearance may change as you
tighten the lock nut. Experiment with tightening technique to maintain clearance as you
tighten, and recheck the clearances after all four valves on one side have been adjusted.
The two exhaust valves are located nearest to the exhaust pipe. Adjust exhaust = .012
in (.30 mm). Adjust intake = .006 in (.15mm). Rotate engine 360 degrees, center OT in
timing hole, and adjust the valves on the other side.
ROCKER ARM SIDEPLAY ADJUSTMENT
Mick McKinnon points out that there is one additional gap to check while the valve
covers are off. The rocker arms, which are the vertical metal pieces that contain the
valve adjustment nuts, will move up or down when pushed by hand. Measure the two
gaps where the rocker arms contact the horizontal piece at the bottom. This horizontal
piece has several names, including lower rocker arm bearing carrier (LRABC) and
rocker arm end plate. This lower rocker arm bearing carrier (LRABC) is held in place by
three T45 torx screws in a triangle pattern (on its side) and one large head bolt. The
gaps should be between .05mm and .30mm. The smaller the gap the quieter the
engine. The procedure is to loosen the 3 Torx screws and, after marking the lower head
bolt, loosen it also. Snug them back up just enough to hold an adjustment and then tap
the LRABC until you have about .05mm end play (gap). Check the gap after tightening
because it may tighten up slightly as you torque the screws and bolts back to spec.
Retorque the T45 torx screws to 15 ft.lb. Retorque the head bolt to 17 ft.lbs. and then
turn the bolt an additional 180-degrees (torque it and then move the wrench through
another half circle).
Clean valve covers and reinstall; the gasket surface MUST be free of all oil film or they
won't seal. Be certain the center donut gasket is in place on the valve cover !!! Reinstall
sparkplug, plug wire and valve cover strip; alternator cover - reinstall top right Allen bolt
first; timing hole plug - be careful when reinstalling this plug that you do not push it all
the way through, into the hole. Editors Note: One trick is to stab the rubber plug in the
middle with a sharp awl to hold it in place while you carefully push the edges in with a
long screwdriver.
Copyright© 1997, Stephen Karlan(Dali Meeow) <dali@netrox.net>, Miami, Florida
40
Clutch Adjustment - Paul Glaves
The clutch adjustment at the hand lever specified as 7mm when resistance is felt
is a bit deceptive, or at least ambiguous. Proper clutch adjustment procedure -
which BMWNA says is critical to proper clutch operation is:
a. adjust the knurled adjuster at the hand grip so that exactly 12mm is between
the knurled adjuster and the knurled lock ring.
b. Loosen the 13mm lock nut on the adjusting pin (small bolt) on the clutch lever
at the rear of the transmission. Rotate the 10mm head on the adjusting pin until
there is 7mm play when the clutch lever is pulled, measured as shown in the
owners (riders) manual. Tighten the locknut. Old trick: To keep the adjusting
pin from rotating out of adjustment as you tighten the lock nut, simply pull in the
clutch. This puts pressure on the pin and keeps it from turning if the threads are
clean. What is light resistance? They are really talking about free play, where
the pull is only against a small spring and not against the clutch pressure plate
spring itself. This is an easy one finger pull up until you are trying to compress
the pressure plate spring.
41
Clutch Adjustment - Bob Gorman
A just released service bulletin revises the clutch freeplay specification to 12mm
between the knurled nuts and 7mm at the lever. This is revised from 10mm and
5mm respectively.
It appears that improper clutch adjustment has been the cause of many shifting
problems. In order to obtain the new clearances you'll need to adjust the clutch at
the motor. You can have your dealer do it next time you have service or you can
easily do it yourself.
Equipment:
13mm deep well socket
10mm socket
socket swivel attachment
socket wrench
6" socket extension
13mm box end wrench cutoff to 2"
Procedure:
Place the extension on the wrench
place the swivel on the end of the extension
place the 13mm socket on the swivel
approach from the left side of the bike
reach in and just crack loose the 13mm locking nut at the rear of the tranny
place the 2" 13mm box end over the locknut. This will keep it from turning
remove the 13mm socket and replace it with the 10mm socket
reach in and back out the 10mm adjusting nut until you achieve spec.
give the 10mm nut another 1/2 turn
remove the 2" 13mm wrench from the locking nut
replace the 10mm socket with the 13mm socket
reach in and tighten the lock nut.
In the process the 10mm will regain that 1/2 turn you put in.
The entire adjustment takes, maybe, 2 minutes.
42
Brake Bleeding - Stephen Karlan (Dali Meeow)
R1100 and R850 yearly maintenance requires replacing (by bleeding) the brake fluid.
RECOMMENDED FLUIDS
Use only fluids from a new, never-been-opened container. The manual calls for: BMW
DOT4, Castrol Disc Brake, DOW ET 504 Shell Donax DOT 4, Hydraulan DOT 4. None
of these is a synthetic. Use the recommended fluids. Synthetics (DOT 5) are not
approved and may not be compatible with the R1100.
WARNING: Brake fluid wrecks (eats) paint immediately and must NOT come in contact
with any part of your bike!!!
Place bike on center stand for easiest access. The front brake reservoir is located on the
right handlebar and is part of the brake casting. The reservoir top measures 2-inches x
1 7/8-inches and is held on with four screws; rotate and secure the handlebar so that the
top is level. Protect the bike with a large plastic garbage bag under the front reservoir
and the right front bike area; place paper towels or rags on top of the plastic to capture
any brake fluid that escapes. The rear reservoir is a clear plastic bottle located on the
right rear of the bike; you must remove the side fairing piece to see it. When working
with the rear reservoir, the right-side plastic fairing parts must be removed and a plastic
bag may be taped so that it is held behind the reservoir and drapes down to protect the
area where fluid might leak from the rear reservoir.
WARNING: Maintain fluid in the reservoir at all times (do NOT allow air into the brake
lines)!!!
METHOD ONE:
Mityvac(r) is a hand-held vacuum pump that attaches to the bleeder valve on the caliper
and pulls brake fluid from the reservoir, through the brake line and nipple, into a plastic
line and deposits the fluid into a cup built into the tool. There is a plastic model (Part
NO. 7000) and a metal model. The plastic version is available from some WalMart
Stores for approx. $25. Metal models cost about $60 and are available from Mac Tools
(part number MV4000) and Snap-On Tools (private vendors who sell to auto repair
shops and may be found in the telephone book), and from Imparts at 1-800-325-9043,
part number 29900. Sears also sells a vacuum pump (about $35) and a brake bleeder
kit (about $10) which work well.
A Mityvac(r) vacuum pump tool is designed for bleeding brakes; read the Mityvac
information you receive with the tool. If you are not using a Mityvac or similar tool, the
difference will be explained in the paragraphs under Method Two. Both methods will
yield the same excellent result if performed properly.
Replace the fluid in the handle-bar mounted reservoir by using a turkey baster or other
device to get the old fluid out and then refill with new fluid, and do the same with the
reservoir under the seat on the right side of the bike. (Protect your paint and use
something (cup/paper/rags) to catch the drips from the turkey baster, because the
turkey baster will drip.) Fill the reservoirs with one of the recommended fluids. Now
follow the cycle of the four basic steps.
Cycle of four basic steps: (1) Create suction at the bleeding nipple which is on the
caliper, (2) Drain most of the fluid from the reservoir by opening the bleeding nipple , (3)
43
Close the bleeding nipple while fluid is STILL COMING OUT and BEFORE the reservoir
is empty, (4) Add more fluid to the reservoir and start this cycle again. Memorize step
#3.
The brake nipple is located on the caliper body. Stand to the left side of the bike and
look at the front wheel. The tire is mounted on the rim. The brake disc (rotor) is smaller
than the rim, made of shiny metal with holes bored in it. At the one o'clock position there
is a black metal caliper with the word "BREMBO" in metallic relief on the body. A rubber
hose containing the brake fluid is attached to the top of the caliper. Also on the top of
this black caliper is a rubber cap that covers the metal nipple. The nipple sticks up, has
a hole in its center, is smooth and round at the top and the base is a six-sided bolt.
Remove the rubber cap and clean the nipple before using it.. When the nipple bolt is
rotated (looking down at it) counter-clockwise it becomes loose and brake fluid may flow
out of the brake system through the center hole.
Position the bike and secure the handle bar so that the handle-bar reservoir is level with
the ground or slightly tilted so that the hose connection is the lowest point. Using an
11mm box end wrench or socket to open the nipple may help prevent problems if it is
very tight. Start on the left front caliper (furthest from the reservoir). Open the reservoir
top.
Step one: Attach the Mityvac suction hose to the nipple and pump the tool to create
suction. Make certain the reservoir on the tool is attached and the tool is functioning;
and you might even try reading the manual for the tool. Pump the tool to create a
vacuum. Consider the following: You may wish to seal the nipple-hose connection area
with grease so that ambient air is not sucked into the hose. In this way, if there was no
air in the brake system there will be no air in the spent fluid cup. Many mechanics don't
seal the nipple-hose connection with grease because air in the spent fluid does not
affect the bleeding procedure, they do not mind seeing the air bubbles because the
spent fluid will be discarded and they do not check it for bubbles, and therefore they
consider greasing the nipple as an unnecessary bother.
Step two: Slowly and carefully open the nipple and observe the fluid level in the bike
reservoir carefully. When you look at the hose that is attached to the nipple you will see
bubbles in the hose. The bubbles are from air being sucked into the line around the
nipple area as well as any air that may be in the system. Step three: When the amount
of fluid in the reservoir decreases by 50%, turn off the flow by tightening the nipple
(clockwise). As you are tightening the nipple, the Mityvac must still contain some
vacuum , some fluid flow must be taking place so that air can not enter the system, and
the reservoir must contain some fluid. Step four: Add brake fluid when 50% or more of
the fluid has been vacuumed (drained, suctioned) from the bike reservoir. Repeat these
four steps until the fluid appears clear in the tube leading to the Mityvac reservoir jar.
When the fluid is clear, tighten the nipple and replace the rubber cap. Move to the right
front caliper of the bike and repeat the four steps until the fluid appears clear again.
When finished with the right side, replenish the brake reservoir and replace the cap and
screws. Fluid should be at the top of the reservoir site window.
Move to the rear disk and bleed the rear reservoir from the nipple on the rear caliper until
the fluid is clear. Replace the rubber cap on the nipple, replenish the reservoir and
replace the cap on the rear.
44
After the fluid has been completely replaced and all nipples are tight, check that the
front and rear reservoirs are filled and secure. Slowly pump the front brake lever, then
pump the foot pedal until there is a solid feel. Continue pumping the brakes for a few
minutes, then recheck the reservoir level and refill if necessary.
WARNING: You must pump both front and rear brakes to confirm that they are
responding with a solid feel BEFORE you ride the bike!!!
Note on brake fluid level: Before replacing brake pads, remove brake fluid so that it is
NOT at the maximum level. New brake pads will take up some of the brake fluid space
in the system; if the brake fluid is at maximum level it probably will overflow the reservoir.
METHOD TWO.
No Mityvac is used in Method Two. This method is used by many auto mechanics who
use the brake master cylinder to create the pressure needed to force fluid through the
brake lines. You will not be using the suction created by the Mityvac.
Replace the fluid in the handle-bar mounted reservoir as described in Method One.
There are still four basic steps in Method Two, but number one has been changed. The
steps now read: (1) Keep the reservoir cover in place to prevent fluid from squirting up
(which will create havoc with your paint) and attach a drain tube and jar to the caliper
nipple to catch any fluid that will be drained from the nipple. Pump the brake lever to
insure that the system can create pressure. Now, pull the lever gently (as in applying
the brake) while you perform the next two steps. Do NOT allow the lever to return to its
open position until the next two steps are complete!!! (2) Gradually open the bleeding
nipple at the disk caliper approximately 1/2 turn (3) Close the bleeding nipple while fluid
is STILL COMING OUT and BEFORE the reservoir is empty, (4) With the caliper nipple
closed and the reservoir cover still in place, release the lever. Understand and memorize
step #3. With this method you are replacing the brake fluid one “squirt” (i.e. one press of
the brake lever) at a time and repeating until clear fluid emerges from the drain tube
connected to the bleeder valve. Keep an eye on the reservoir during these steps and
refill whenever it goes down to 50%.
Be extremely careful with the bike's brake fluid in the handle-bar mounted reservoir!!!
Follow the same procedure that is described in Method One. Start on the left front and
bleed the fluid until it is clear in color. You must close the bleeding nipple to turn off the
flow by tightening the nipple while the fluid is still coming out, and this means
maintaining a small amount of pressure on the brake lever and maintain some fluid flow.
If you take the pressure off the brake lever while the fluid is still coming out, you may
introduce air into the brake system and this is bad. Read "Air in the System" below.
(You may be able to locate a "One Man Brake Bleeder" which is a one-way valve that
attaches to the bleeder nipple and prevents air from entering through the bleeder nipple.
When using this, instead of opening and closing the bleeder valve, you just pump the
master cylinder until the fluid runs clear and being careful to keep brake fluid in the
reservoir. Do not let the reservoir run dry; this will pump air into the system.) You are
finished with the left side when discharging fluid is clear and the caliper nipple is tight.
Repeat this procedure with the front right caliper. Make certain the front brakes are
finished, the front nipples are tight, and the front reservoir cover is secure with the four
screws. It is now time to bleed the rear brakes using the same procedures.
45
Attach the drain tube and jar to the rear caliper nipple and repeat the four steps with the
rear brakes. Gently and carefully actuate the rear brake while releasing the nipple on
the rear brake. Observe the rear reservoir closely and replenish as needed.
Discontinue pumping when the fluid is clear; close the nipple as fluid is gradually flowing
out.
After the fluid has been completely replaced and all nipples are tight, check that the
front and rear reservoirs are filled and secure. Slowly pump the brake lever, then pump
the foot pedal until there is a solid feel. Continue pumping the brakes for a few minutes,
then recheck the reservoir level and refill if necessary.
WARNING: You must pump the brakes and be certain the brakes are responding with a
solid feel BEFORE you ride the bike!!!
TROUBLE SHOOTING
AIR IN THE SYSTEM --- The brake system works with brake fluid. You push on the
brake lever and this force is transmitted to the brake piston at the discs and causes the
pads to grip the discs. The more you pull on the brake lever, the more pressure you put
on the discs and the faster you stop. There is fluid in the brake lines that transmit this
force; you cannot compress this liquid fluid. But if there is air in the brake lines, even a
little, this will cause problems because air compresses. If you pull on a brake lever and
there is air in the brake line, the air will compress and less force will be transmitted to the
brake pads.
If you feel air in the brake lines (spongy brakes), you MUST bleed the brakes until all of
the air is expelled!!! If air is allowed to remain in the line, it will compress when the
brakes are actuated and will not give you firm and steady pressure on the pistons and
pads. This will result in uneven and dangerous braking. Soft or spongy brakes feel as
though they are not working because they are not working. The best procedure is to
work so that no air enters the system. If it does get into the system, you must expel all
air from the system.
AIR IN REAR BRAKE SYSTEM
If you get air in the brake system, especially the rear brake system, you will want to start
the corrective process by bleeding from the ABS nipple under the tank. Do this because
air bubbles, which rise, may be trapped in the higher ABS area. Then continue with
either Method One or Method Two. See: TWO OPTIONS.
UNRESPONSIVE BRAKES
If you still have an unresponsive brake system after bleeding the brakes and after
following the procedures recommended here, you may have water in the system or an
ABS problem. Do not ride the bike! Seek professional help.
TWO OPTIONS
The ABS system has a bleeding nipple under the gas tank. You do NOT have to bleed
from this nipple. Old brake fluid will be totally flushed when bleeding from both front and
rear caliper nipples. Bleeding from under the tank will neither hurt nor help your brake
system. The nipple at the ABS unit under the tank may be bleed before starting with the
front nipples at the calipers. Some shops bleed at the ABS under the tank, some do not.
Under tank bleeding is recommended by the BMW manual. However, you should bleed
from under the tank if your bike experiences problems outlined in the paragraphs: " AIR
IN REAR BRAKE SYSTEM" or "UNRESPONSIVE BRAKES'
46
Brake pads may be retracted (pushed in) while bleeding the brakes. A minute amount of
brake fluid will be forced into the system with this maneuver. There are contrary
opinions about whether this procedure is beneficial. Note: The pads may be pulled in by
suction when Method One is used in bleeding the brakes. Retracting the brake pads is
part of the bleeding procedure recommended in the BMW manual.
SPEED BLEEDER (a new third method)
This new product is a one-way valve that looks similar to the standard bleed nipple at the
caliper, but replaces it. It operates like the standard bleed nipple, opening when turned
counter-clockwise and allowing brake fluid to flow from the nipple at the caliper. The
advantage of the Speed Bleed is that it is manufactured with a check valve that
prevents air from entering the brake system at the nipple. Turning the Speed Bleeder
clockwise closes it, just like a standard brake nipple. This will simplify bleeding the
brakes because you will not have to open and close the nipple every time you pump
brake fluid out and air will not enter the system from the nipple.
Each Speed Bleeder costs approximately $8.00. The manufacturer has been accurate
in determining the correct thread size; if you are not certain about sizing, ask him. You
will need one Speed Bleeder for each brake caliper, and one for the nipple under the
tank if you are bleeding from this ABS location.
The contact information is: Speed Bleeder Products, P.O. Box 306, Lemont, Illinois
60439, (630) 739 - 4620 phone, (630) 739 - 9626 fax, eMail to: speedbleeder@super-
highway.net and web site at http://www.speedbleeder.com
The Speed Bleeder has operated as advertised in our limited trials. Several BMW riders
are using this product, and all reported results have been positive. This author has had
excellent results. When using these, ensure that (1) air is not entering the system
through the Speed Bleeder's check valve, that (2) air is not entering the brake line
through the threaded area between the caliper and the Speed Bleeder, and that (3) the
Speed Bleeder is closed and will not permit fluid to escape at the conclusion of bleeding
the brakes. A firm brake lever after bleeding will normally mean that the Speed Bleeder
worked correctly. Exercise the same precautions and the same "firm brake lever" test
you must make when using the standard nipple. Warning: When installing these, do not
seat them too far into the caliper. They must be seated only far enough to prevent brake
fluid from escaping. I have a report of one person who broke a Speed Bleeder off in the
caliper.
The complete version of this article is available at www.ibmwr.org
Copyright© 1997, Stephen Karlan(Dali Meeow) <dali@netrox.net>, Miami, Florida
47
Changing the Fuel Filter on an R1100RS - Jon Diaz
Here is the procedure to change your R1100RS fuel filter. It took me about 90
minutes the 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
the fuel pump plate, and two standard BMW fuel line clamps just like the ones
used on the fuel lines by the right side throttle body (point to these on your bike if
your parts jockey doesn't understand). Let your sealing O-ring lie out for a few
days before starting the job.....I didn't and had trouble later. Let the fuel level run
down, way down, so low you don't think you can make it back to the gas station.
It still won't be low enough so you might want to siphon out from the top as well.
Get as much fuel out as possible. Drain, swirl the bike, drain some more. OK?
Remove the left and right fairing panels, the seats, and the right fuel injector
cover. Unplug the right fuel injector wire and the fuel pump harness. The fuel
delivery hoses run behind the cross-over throttle cable, and most people will
have too many fingers to keep all that stuff plugged in. Remember that there are
also two screws tying the upper fairing to the gas tank, and two little screws
holding the left and right inner panels (the ones with the rocker switches/RID) to
the gas tank. Those screws must be removed.
Remove the screw holding down the back of the gas tank, and keep track of the
grommets used to fill the gap between the frame and the tank. They like to fall
out....
Unplug the vent lines right next to the airbox, and loosen both fuel line clamps.
The top fuel line is holding the fuel....when you pull it, you will need to drain into a
gas can until it stops, otherwise there will be a tremendous mess. When it is
done draining, remove the other hose and lift the tank off the bike.
I laid the tank on a towel on my garage floor, right side down. Mark the
orientation of the pump plate and then loosen it; carefully pull the inside vent
lines off the plate, and gently rotate the whole assembly out. Hold the assembly
with your right hand, and use your left hand to guide the fuel level sender and
fuel pump screen through the hole in the side of the tank.
I carried the fuel pump/filter works to the bench. Anyone familiar with a K-bike
will recognize everything here except the fuel filter is held in with compression
clamps. I pried those clamps off, pulled the hoses from either end, removed the
old filter and inserted the new one, and tightened the works down with the
aforementioned screw-type clamps.
48
Look at the fuel level sender rod while you have the parts out. There should be
an E-ring type circlip holding the float to the rod, but some of the early bikes were
missing these and had their floats bobbing around the tank rather than
registering fuel level.
I carried the assembly back to the gas tank. The O-ring must be pressed down
into the groove, the vent lines forced back on the plate, and install the plate
exactly as removed. Start all six screws, and tighten in a cross pattern. I tilted
the tank back up after this operation to try and get the O-ring to leak. After 30
minutes or so, nothing had come out. I would suggest doing this as well to avoid
having to re-remove the tank to fix a leak.
Reinsert the fuel tank, and the lines pretty much fall into place. I added some
gas to the tank because you don't want to run these roller cell fuel pumps dry for
any reason. I would also coat the fuel injector and fuel pump connector pins with
dielectric grease to deal with the moisture and corrosion that the bike sees daily
in some cases. Reinstall all body work and all the screws you removed.
Tighten the clamps on the fuel lines and reattach the vent lines by the airbox.
Start the bike, check for leaks, and if all is well, ride the hell out of it for another
year!
49
External Fuel Filter Modification - Rob Lentini
After I bought my ’87 K75S I soon found it interesting (and strange) that the fuel
filter was installed inside the fuel tank! Most fuel-injected cars that I’ve worked on
have external filters, so I wondered about the theory and reasoning for designing
the filter location this way, but it wasn’t a big deal on that K. One can quite easily
access the filter by removing the fuel filler cap assembly and then reach into the
tank with tools and a hand to remove and replace the filter per BMW service
intervals. Mind you, one still has to run the tank mostly dry and then contend with
modern fuel carcinogens on his or her skin (use surgical gloves!). But, filter
replacement isn’t a big deal on K bikes.
Type 259 Boxers (Oilheads) are a completely different story, however. Sure, the
filter is (for some reason) still mounted in the tank like the K bikes, but the big
difference is you can’t see the filter from the filler opening regardless of whether
the filler assembly is removed or not. You can’t even reach the dang thing with
your hands. Besides, you don’t even want to attempt to blindly remove and
replace the filter this way or your hand or tools would likely damage the fuel level
float rheostat assembly ($$$)!
On my RS, with close similarities to RTs, GSs, Rs, Cs and I suspect the S, the
fuel filter is part of one main assembly that holds the fuel pump, fuel level
float/rheostat and filter all together as one unit. This unit is, in turn, mounted to
the right/inside flat surface of the fuel tank using a circular flange fastened by six
Allen head machine screws. A large "O" ring seals the interface to prevent leaks.
To replace the fuel filter, one must remove the fuel tank and them remove the
above assembly to gain access to the fuel filter. Even careful removal of the
assembly from the tank risks damage to the fragile fuel level float mechanism
since the darn thing is a tight squeeze in the fuel tank and needs some
"maneuvering" to get it free and clear.
BMW recommends that the fuel filter be replaced every 24,000 miles, or 12,000
miles if fuel is of poor quality. I can vouch from experience that only one bad load
of water-contaminated fuel is enough to clog these filters and bring the motor
(and your ride!) to a halt. I therefore decided early on with my K to replace this
filter more often. I wanted to do the same on my R1100RS but soon discovered
the process was a hassle. Was there a better way?
There is a better way! I’ve found a sanitary and safe method of installing either
the OEM BMW filter or a less expensive aftermarket variety conveniently outside
of the tank where it may be easily serviced in minutes. Here’s how:
DISCLAIMER:
50
This is a non-stock, non-BMW approved method of placing the fuel filter outside
of the tank. Some others and I believe this to be safe if correctly accomplished by
a knowledgeable person using proper parts, procedures and tools. DO THIS AT
YOUR OWN RISK.
MATERIALS REQUIRED:
1. 6 ft of 5/16 (7.9 – 8.00mm) fuel injection hose. It is VERY important to ONLY
purchase fuel injection-rated hose since up to 42 psi exists in the fuel system! It’s
expensive (~$4.00 per ft) but don’t EVEN consider regular hose.
2. Original (expensive!) BMW filter or steel-bodied Deutsch FF401 or FF424 filter
(both Deutsch’s are the same except for unneeded hose adapters/clamps with
the FF424) available at Auto Zone (~$2.00). The FF401/424 are for various and
sundry small and big car gas and diesel engines ranging up to MOPAR 440 cubic
inch V8s. Another suitable filter is the larger Deutsch FF507. DON’T use the
Fram G2 nylon-encased equivalent. The high 42 psi fuel pressure could burst a
non-metallic fuel filter case!
3. 8 fuel injection hose clamps, size 12.5 or 13mm (or inch equivalent). These
are the typical BMW style "squeeze together" clamps, NOT worm gear types.
Again, these are also available at BMW or auto parts stores. You only really need
6 of these since two on your bike are reusable, but 8 if you want all new
hardware.
4. Size 28 "Adel" aircraft cable clamp to belay the fuel filter to the transmission.
This clamp fits the Deutsch filter. A larger diameter clamp will be required for the
BMW filter since it’s slightly wider. Clamps are available at some specialized
hardware stores, electrical shops, or alternatively the filter could be plastic cable-
tied (with rubber cushioning). I recommend a clamp.
5. New sealing "O" ring for the fuel pump assembly.
6. Longer brake line clamp screw, 4 x 22mm with ~3mm spacer
PROCEDURE (in accordance with tank and fuel filter removal/replacement steps
of the BMW or Haynes manual, plus those below):
PHOTOS: filter1, filter2, filter3, filter4, filter5
view photos at:
http://www.ibmwr.org/r-tech/oilheads/extern_fuel_filter.shtml
1. Drain (siphon dry) and remove the fuel tank. Don’t forget to disconnect the two
electrical connectors! Observe and label which hose you removed from the tank
to each plastic fuel distribution line that goes between the cylinders (through the
engine from right to left). You’ll also need to disconnect the two small rubber vent
lines at their unions above the right throttle body.
2. Remove the fuel pump assembly from the tank (six Allen screws).
51
3. Observe the fuel filter mounted on the removed fuel pump assembly. Loosen
the four crimped hose clamps and remove the filter and two short fuel hoses.
One of the fuel hoses has a 180-degree bend, for reference.
4. Replace the filter, two hoses and four crimped clamps with ONE 10" length of
new fuel injection hose and two new fuel injection clamps. Loop the new hose
180 degrees to bypass the entire fuel filter setup you just removed. Be sure to
align the hose and clamps for neatness and non-interference with the fuel level
float.
5. Reinstall the fuel pump assembly (with new "O" ring) onto the tank. Be careful
to NOT over torque the six Allen head screws, since the nut plates in the tank are
known to sometimes strip out.
6. Observe the two fuel injection hoses leaving the outside of the tank from the
pump assembly. The UPPER hose is the "return" hose and the LOWER is the
"supply" or pressure hose.
7. Replace the UPPER fuel injection hose with the same length new hose. Use
another new clamp at the fuel pump end.
8. Replace the LOWER fuel injection hose with all of your remaining new hose. It
will be cut twice later. Again, use a new clamp at the fuel pump end.
9. Install the tank. Don’t forget the electrical connectors and vent lines. Smile!
You will NEVER have to remove it again for filter replacement!
10. Install the UPPER "return" hose, with new clamp, to the UPPER plastic
distribution line.
11. Run the entire length of the LOWER "supply" hose along and under the
UPPER "return" hose. Continue to route it towards the rear, above the clamp
holding the steel brake lines, then inside and out to the right BETWEEN the two
brake lines just forward of the rear subframe mounting boss casting on the
transmission.
12. Mount your new filter using the cable clamp, the 4mm diameter longer screw
and the spacer in place of the screw where the brake lines are clamped to the
transmission casting below the right throttle body. The filter fuel direction arrow
should be pointing forward. The center fuel filter circumvential flange on the
Deutsch should be forward of the clamp.
13. Carefully gauge the correct length of fuel hose needed to make a neat 180-
degree turn and connection to the input (rear end) of the fuel filter. Cut and install
the "supply" hose to the rear of the filter using another new clamp. Position the
open ends of the clamp down before tightening.
14. Now install the remaining length of fuel hose to the outlet (forward end) of the
filter, again using a new clamp. Feed the new hose forward, up and inside of the
52
inlet tract of the right throttle body towards the input of the LOWER "supply"
plastic distribution line.
15. NOW THIS IS IMPORTANT! Cut the remaining hose to allow a smooth
generous arc that contacts the cylinder finning and does NOT interfere with
throttle operation. Start longer than you think and trim a little at a time to allow for
a smooth arc and NO throttle mechanism interference on the right throttle body.
Now install your last new clamp at the LOWER "supply" plastic distribution line.
16. RECHECK ALL WORK, SANITIZE THE LAYOUT, RECHECK THROTTLE
OPERATION, DOUBLE CHECK ARROW DIRECTION ON THE FILTER!
17. If all looks OK, start the engine and check for leaks.
18. Test ride the motorcycle. After the ride, AGAIN check for throttle interference.
If you made the forward loop long enough the hose will generously clear the
throttle mechanism.
Well, that’s it! You can now change out the filter in minutes and with no hassle.
You will never have to go into your tank again. The aftermarket Deutsch filter is
cheap, works fine, and encourages replacement every major service at 12,000
miles—a good practice. The Deutsch also works fine in Ks.
ONE FINAL NOTE:
I personally thank noted wrench Joe Katz for this "loop" installation method, for
which I give him full credit. I had originally installed a much smaller filter along the
"supply" line without a loop above the right throttle body. This seemed to work
until I observed that the Fram 3606 filter I was using at the time would inhibit fuel
flow at wide open throttle, dropping fuel pressure and causing fuel starvation
initially on the right cylinder—NOT good! Curiously, the similarly sized Deutsch
FF330 I previously had installed didn’t cause this. Anyway, I wanted to use the
larger OEM size filter but couldn’t see the obvious "Katz" solution. Thanks, Joe!
As always, questions are welcome. Happy Wrenching!
Editor’s Note: R1100GS/1150GS riders are placing the external fuel filter on top
of the air box.
Synchronizing R1100 Throttle Bodies - Bob Gorman
This is and will continue to be a hot topic amongst R1100 owners. Properly
synched throttle bodies will greatly reduce surging and vibration but getting them
synched and keeping them synched is probably the most difficult of any BMW
motorcycle to date. Dealers were required to purchase a $1000.00 special
instrument in order to properly synch the big twin but it can be done with the
conventional Carb-Stix. It is easier with the special tool which electrically
dampens the sensitivity of the throttle operation but I have had very good luck
with the Carb-Stix for over 50,000 miles.
53
First attach the Carb-Stix to the each throttle body by removing the black
vacuum hose on the underside and attaching the Carb-Stix. It is not necessary to
plug off the removed vacuum hoses. If you have fuel injector covers on your bike
remove the right side cover only. We will perform the synching operation with the
bike running. It must be at normal operating temperature, but take care to not let
it overheat. If you cannot complete the operation in 5 minutes then let the bike
cool a bit and try again or use a fan to keep cool air flowing over the bike.
There are only two adjustments that can be performed on the R1100 throttles,
idle and throttle cable. The idle adjustment is accomplished by turning the brass
screw on each throttle body. They are big screws so you can't miss them. DO
NOT set the idle speed by manipulating the throttle stop screws like the older
twins. The starting point for the idle screw setting is 1 1/2 turns out for the RS
and RT and 2 turns out for the R and GS. Before setting the idle make sure you
loosen the right side throttle cable. There can not be any pull on either cable.
Start your bike and notice the mercury level rise in both columns. Take care
when dealing with mercury, it is extremely toxic. Turn each brass screw slightly in
or out to get the mercury levels dead even. The actual level is not important, we
just want both columns to be equal. When adjusted correctly the screws should
be within 1/2 turn of one another.
Now we'll go to the throttle cable. Only the right side is adjusted. The throttle
cable is a single cable that extends from the throttle grip to the left throttle body
and then continues over to the right throttle body. By manipulating only the right
side we are synching the right with the left. All we care about is that both throttle
bodies are pulling equal vacuum. With the bike running raise the rpms and watch
the mercury level rise. We want them to rise together and stay even at all rpms.
This is easier said than done. Don't worry too much if they are off slightly. Your
target point is just when all the slack is removed from the cable but before there
is so much tension that your idle is affected.
Make sure the columns are close at 4,000 rpms, the dreaded surging range.
Some tuners like to use the throttle lock to keep the rpms even but I prefer to
continue to raise and lower the rpms instead. Be careful not to chop the throttle
suddenly from high rpm's, as this can potentially suck mercury into the motor. If
you need to make an adjustment loosen, or slacken in BMWese, the 10mm lock
nut on the cable nipple. Turn the 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
freely in the nipple. Make small adjustments, 1/2 half turn in or out can make a
difference. Once you get the mercury columns to rise together and settle fairly
closely at various rpms you are done. Secure the lock nut and check one more
time.
54
If you still feel you just don't have it right you can always have you dealer use
the BMW Synchro on it.
Throttle Body Sync - Jon Diaz
How To Synch Those R1100 Throttle Bodies!
As an R1100 pilot, you've likely felt it: that little hum in the turn signal switch or
the vibrating mirror you can't see out of or worst case, a bike that surges so badly
at part throttle you can't ride smoothly. It's all part of those first days of R1100
ownership, and very easy to deal with.
When you twist the R1100 throttle, the cable actuates a cam on the left throttle
body, which in turn actuates a cable that crosses over to the right throttle body.
The cross-over cable tends to stretch during those first few months of use, and
this is why the cylinders fall 'out of sync' with one another at part-throttle settings
and give you fuzzy mirrors.
I purchased a mercury manometer (Carb Stix) from my local dealer to use for
this procedure. It consists of rigid plastic tubes sitting in a reservoir of mercury at
one end, with flexible hosing attached to the other end to plug onto the taps at
the throttle bodies. You will also need a 10mm box-end wrench, a flat-blade
screwdriver, and needlenose pliers.
Temperature of the motorcycle engine is critical to the success of this operation.
I like to run my bike for at least 15 minutes before returning to the garage to
perform the operation. Too hot an engine is bad as well, so avoid excessive
idling or traffic during your warm-up period. If it is really hot outside, use a room
fan in front of each cylinder to provide a little cooling breeze and temperature
stability.
After the warm-up ride, place the bike on the centerstand. Remove the black
plastic injector covers if your bike has them, remove the vapor recovery tubes
from the bottom side of each injector body, and insert the hoses from the Carb
Stix onto the exposed taps. Hang the Carb Stix from the ceiling with a bungee
cord or something similar so you can see the mercury levels easily from the right
side of the bike.
Then loosen the locknut on the cable adjuster on top of the right-side
55
throttle body cable, because this is where you will make the part-throttle
adjustment. There is no need to fiddle with the cable adjuster on the left-hand
throttle body.
Start the bike. The mercury should come up a few inches in each tube, and if
they are at different levels, this indicates a different amount of air is being drawn
by each cylinder. Using the bypass screws on the top rear of each throttle body,
align the two levels. Small rotation (i.e. less than half a turn) of the screws
should be all that is required to achieve this.
Once the idle balance is set, you should do a part-throttle setting to ensure that
the butterflies are opening identically. Use about 2500 rpm. Hold the throttle
open at the set speed, and adjust the knurled portion of the right side throttle
body cable adjuster with your other hand to align the mercury levels. When the
levels are even, let the bike return to idle (checking alignment again!), and if all is
well, tighten the locknut on the cable adjuster, making sure that the adjuster does
not rotate with the locknut and mess up your adjustment. Sometimes it is easier
to hold the knurled adjuster with a set of needle-nose pliers while you tighten the
locknut with your 10mm wrench. Recheck after tightening, as the adjustment may
change when turning the locknut.
Congratulations, you have done your first throttle synch. Now go out and ride
until you can't see out of your mirrors again.....
56
Throttle Body Synch – Stephen Karlan (Dali Meeow)
An out-of-synch condition develops (R850 and R1100) because the throttle body cables
stretch or because they lose their adjustment. The result is vibration, sometimes unreal
vibration.
The following procedure, which I call the Gorman/Diaz Balance, was developed by Bob
Gorman and Jon Diaz from Chicago. It is a fast and simple procedure that can yield
dramatic riding improvement.
The 1994-96 models have a crossover synch cable; the 1997 model has left and right
throttle cables attached in an upside down "Y" pattern. Use these instructions for the
1994-96 models. If you have a 1997 model, look for the ['97 - ] and follow the
instruction inside the brackets and disregard the instruction given immediately prior to
the ['97 - ] brackets.
Overview:
The throttle bodies will be synched at two rpm levels.
The low rpm synch will be done first. With the bike at idle (1,000 to 1,200 rpm), the large
brass bypass screws will be adjusted. (LBBS in the Glossary at the end of this article
will help you find this part.)
The high rpm synch will be done last. With the bike at 2,500 to 4,000 rpm, the right side
crossover synch cable will be adjusted. (RSCSC in the Glossary at the end of this
article will help you find this part.) ['97 - right side throttle cable will be adjusted.]
Tools needed:
mercury manometer (carb stix) and a way to secure it (several places to obtain the carb
stix are given at the end of this article)
small pliers or needle nose pliers
10 mm wrench
flat screwdriver
pencil and paper.
Setting Up:
Remove the right side black plastic fuel injection plug cover for access to the right side
crossover synch cable ['97- remove cover for access to right throttle cable]. If you have a
lower fairing, remove it to allow air to reach the cylinders and to prevent cooking the
fairing. With the bike on the center stand, retract the side stand, put the transmission in
neutral, turn on the bike and warm up the engine. Jon Diaz
suggests a more enjoyable way to warm up the engine -- take a ride.
Position a fan near the front tire with its output directed at the cylinders equally to avoid
overheating, or use two fans, one directed to each cylinder. If your bike has a Rider
Information Display (RID), allow the oil to heat up to 5 bars, otherwise idle the bike for
five minutes.
Secure the mercury manometers (carb stix) on the right side of the bike, where most of
the work will take place. Use any method that secures the carb stix (and the hazardous
mercury) vertically while the bike is running, such as hanging the carb stix from the
ceiling.
57
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 of the carb stix's flexible plastic tubes to each brass nipple. Make certain that
the carb stix's plastic tubing does not touch hot exhaust parts; the tubing will melt. There
is no need to plug the black vapor recovery tubes.
Starting the Adjustment:
Loosen the right side crossover synch cable by loosening the 10mm lock nut and turning
the knurled knob counter clockwise to ensure that there is slack ['97- loosen right throttle
cable] .
Count the turns you make to lightly seat both the right and left large brass bypass
screws by turning them clockwise with a flat screwdriver. Record this information for
possible trouble shooting later.
As a starting point, back out both large brass bypass screws 1 1/2 turns for an RS or
RT; 2 turns for an R or GS.
Start the engine. The bike may idle rough because it is not in synch. Do not be
concerned about a rough idle at this time. If the bike will not idle at all due to air
starvation, back both large brass bypass screws out by 1/4 turn (ccw) until the bike
maintains a rough idle.
If the bike is idling too fast, reduce the air flow by screwing both large brass bypass
screws clockwise (cw) in increments of 1/4 turn. If the bike is idling too slowly, increase
the air flow by screwing both large brass bypass screws counter clockwise (ccw) in
increments of 1/4 turn. At some point you will not be able to decrease or increase the
idle speed by moving the large brass bypass screws. Return to the setting immediately
prior to the point where the idle was not changed by moving the large brass bypass
screws.
You now have the large brass bypass screws at the starting point for the low rpm synch.
LOW RPM SYNCH:
With the throttle at idle (1,000 to 1,200 rpm on the tachometer) and the bike at normal
operating temperature, turn the right large brass bypass screw clockwise until the
mercury columns in the carb stix are at an equal height. If moving the right large brass
bypass screw does not accomplish equal height mercury columns, then reset the right
LBBS to its starting point and turn the left LBBS clockwise until the mercury columns in
the carb stix are at an equal height. The amount the mercury column rises or falls, its
actual height, is not important. What is important is that both left and right mercury
columns are the same (equal) height.
The goal is to balance the throttle bodies with the large brass bypass screws open as
little as possible (minimum counter clockwise opening). Bob Gorman notes that, when
adjusted correctly, the screws should be within 1/2 turn of each other.
If the bike does not adjust by turning the LBBS clockwise (in), or if the idle speed is too
low (below 1,000 rpm), change the starting point of the low rpm synch by backing out
both LBBS (counter clockwise) by an additional 1/4 turn.
58
HIGH RPM SYNCH:
When performing the high rpm synch, you will be moving the throttle up to
4,000 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
has already been loosened]. The knurled knob should turn without turning or binding the
crossover synch cable.
Adjust the knurled knob so that the mercury columns rise together as the rpm
rises. You may need several turns to take up the slack you created earlier. Some riders
adjust the mercury column heights with the rpm steady at 2,500, some with the rpm
steady at 4,000, and some make this adjustment so that the columns are fairly equal
while the throttle is being opened from 2,000 to about 4,000 rpm. The mercury columns
should be fairly equal if the throttle is held steady or while the throttle is increasing rpm
from 2,000 to 4,000.
After adjusting the knurled knob so that the mercury columns are equal, tighten the
10mm lock nut and recheck the mercury levels. If tightening the lock nut moves the
knurled knob and upsets the adjustment, hold the knurled knob with small pliers or
needle nosed pliers to maintain the adjustment. If holding the knob does not work,
measure the amount of mercury column error after tightening the lock nut. Recording
this measured error, loosen the lock nut and add the amount of measured error to the
mercury column before tightening the 10mm lock nut. This objective is to have equal
mercury column heights after the lock nut is tightened.
Test your work by checking the mercury level at idle and at 2,500 rpm. If not equal, you
should begin again with the adjustment process at "Low RPM
Synch".
Trouble shooting:
If the valves are not properly adjusted and are not equal side-to-side, the cylinders will
not be getting an equal amount of air-fuel and the throttle bodies cannot be
balanced.
Check that the air supply tube-throttle body connection is aligned, that the air supply
tubes are fully seated at both ends and that the clamps are correctly aligned
when tightened.
If, after satisfactorily completing the synch, the bike begins to vibrate wildly, check to see
if a small stone or other debris has become lodged in the throttle cable pulley.
This is a common problem.
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Where to buy carb stix, mercury:
Precision Manufacturing Services at 800-237-5947 was selling the Motion Pro brand for
$36.95 + shipping in 1996.
J.C. Whitney has a Motorcycle Accessories and Parts Catalog for $1. They show several
types of vacuum gages and mercury manometers. Their address is P.O. Box 3000,
LaSalle, Illinois 61301, phone 312-431-6102; fax 312-431-5625.
59
Donelson Cycles Inc. at 800-325-4144 was selling the Motion Pro brand for $34.45
including shipping in 1996.
Ask you favorite cycle shop or mail order company for their price.
If the mercury comes out of the reservoir (because it tipped over or the cat hit it), you
can get it from Chaparral Motorsports 1-800-841-2960 part# 315-0441 for $9.99.
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Glossary:
RSCSC - Right side crossover synch cable ['97- right throttle cable].
On the right side of the bike, forward of the fuel injection plugs and between the
engine and the throttle body, you will find this vertical cable. The cable is secured on a
bracket with a lock nut on the bracket and a knurled knob above the lock nut. After
loosening the lock nut, turning the knurled knob will either lengthen or shorten the cable.
If the top of the cable is pulled gently up, it should come out of the knurled knob. This is
the mechanism that must be adjusted to vary the mercury columns.
LBBS - Large Brass Bypass Screw:
On the right side of the bike, on the outer surface of the throttle body tube is a
large brass bypass screw with a slotted (NOT Phillips) head that faces toward the rear of
the bike. If you were to place a screwdriver on the screw, the handle of the screwdriver
would point toward the right rear turn signal. This large brass bypass screw is
approximately one inch forward of the black plastic air intake tube. You are looking for it
on the right side because it is easier to locate there; there are fewer things in the way.
You can see the large brass bypass screws easily when standing near the turn signals.
If you look on the left side, you will find a similar
large brass bypass screw. The official BMW Repair Manual calls this a "recirculating air
screw" at page 00.27.
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Note: The throttle cables on many 1994-96 bikes were replaced with Teflon coated units
(warranty service bulletin #2748 dated 7/3/96) because the inner cable was sticking.
The improved cable was installed at the factory after the following VIN number:
R1100RS 0312537
R1100GS 0381479
R1100R 6379238
R1100RT 0440499
R850 from start of prod.
If the older type is installed on your bike, and if it has not been replaced, see your dealer
because some older cables caused significant balancing problems.
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Author's note: I tape new throttle cables open to speed-up stretching and break in. The
original throttle body synch work by Jon Diaz can be found at
http://www.ibmwr.org/rtech/R11-throttle-sync.html Bob Gorman's original throttle body
synch work appeared in a local newsletter and the original tune-up manual.
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Copyright(c) 1997, Stephen Karlan (Dali Meeow) <dali@netrox.net> , Miami, Florida
Throttle Position Sensor - Bob Gorman
The throttle position sensor is located on the left throttle body. It is the black box
with an electrical plug extending from the bottom. The sensor is what ties the
mechanics of the throttle cable to the electronics of the Motronic.
The Motronic needs to know the position of the throttle so it can regulate gas
flow, timing, and other engine management functions. As you turn the throttle,
voltage is adjusted up and down in the sensor and relayed to the Motronic.
If you pull down the rubber cap from the electrical connector on the sensor you
will notice 4 wires. The wire closest to the rear (number 1 – red/white) is effected
by throttle openings up to 1/8th turn. Most surging occurs at very small throttle
openings so we want to make sure that the baseline voltage is correct. Our goal
is to equate a closed mechanical throttle with .370 to .400V.
Place the positive lead of the DVM (Digital Volt Meter) up into the plug
corresponding to wire number 1(red/white). On the newer bikes there is an
internal seal around the wire so use a needle or paperclip to penetrate the seal
and make contact with the wire. Attach the ground wire to a good unpainted bolt.
Turn on the bike but do not start. Note and record your initial TPS voltage so
you can go back to it if necessary. The voltage should read between 370 -
400mV. If not you'll need to loosen the two screws holding the sensor in place
and slowly rotate it one way or the other until the correct voltage is achieved.
Don't worry about messing it up, you can't. After the sensor reading is set, tighten
the sensor screws.
One last step, if the voltage during the setup process went above 400mV then
a fault may have been generated in the Motronic. This is easily reset by pulling
the number 5 fuse from the left and then replacing it. The Motronic is now reset
and the throttle position setting is right on spec.
61
Throttle Position Sensor - Rob Lentini
Note: the following information has been updated in the “Zero = Zero R1100
Throttle Position Sensor Tuning” article in the Super Tuning section of this
manual. The following information is intended primarily for people who wish to
adjust their TPS but do not want to change the factory sealed throttle body stop
screw on the throttle body.
Here’s what I know about Throttle Position Sensor (TPS) settings on my bike an
R1100RS. I also suspect that this information will apply to the R1100 GS, RT,
and R also.
Locate connector #1 on your TPS - it is to your right as you face the TPS or the
rear most connector (red/white wire). All of my readings were taken with a high
quality Fluke 79 Digital Voltmeter (DVM) with the positive lead to the TPS and the
negative to the engine block. I used a paper clip to probe inside the TPS
connector. Readings may be taken with the engine running or not, though I
observed a very slight (2-3mv) change between the two states. Ignition must be
on, engine cutoff switch in the on position, and the sidestand retracted to make a
reading.
The voltage range at #1 is .370 - .400 volts at idle to a smooth increase with
throttle to 4.77 volts at about 1/3 throttle opening. There is no further increase to
wide open throttle. Thus this part of the TPS appears to control idle and off-idle
primarily. Publicized idle values as set by the BMW analyzer are the source of
the above .370 - .400 figures. These values appear valid, though changes to
individual machines may be advantageous.
It appears that for machines operated primarily at higher altitudes (above
perhaps 4000 ft.), setting pin #1 TPS voltage to .370 or even slightly lower can
improve performance. Conversely, if a machine is operated at sea level, #1 could
be set for .400 to fatten up the fuel/air mixture slightly.
Performance-wise here is what I observed and concluded:
-TPS #1 values of .370 or less reduce surging, reduce throttle response, and
increase backfiring tendencies. Too low a setting could cause pinging,
overheating, and catalytic converter damage.
-TPS #1 values closer to .400 or even slightly above don’t necessarily increase
surging, but they do improve throttle response and reduce backfiring. Too high a
setting could violate emissions regulations, damage a catalytic converter, and
increase fuel consumption.
62
Throttle Screw and TPS Adjustment - Stephen Karlan (reviewed
by Rob Lentini)
I. The Problems.
Surging -- A condition of increasing and decreasing power, cycling back and forth, when
the throttle is held absolutely steady at a fixed rpm (such as 3,500 rpm while using a
throttle lock, tape or rock-solid hand). The electronic control system is hunting (up and
down) for the correct air/fuel mixture and the engine is not responding to throttle input
but to electronic sensors.
To minimize surging, the throttle plate screws (two) and the Throttle Position Sensor
(one TPS on the bike) are adjusted using a voltmeter. (There can be other factors, but
an incorrectly set TPS is the 95% problem.)
Vibration -- Shaking or oscillating. When the throttle is held in a fixed position, the
vibration is constant and unchanging. It may vibrate more at one throttle opening (rpm)
than at another; i.e. it may vibrate more at idle (or is more noticeable at idle) than at
3500 rpm.
To minimize vibration, the throttle bodies (one for each cylinder on each side of the bike)
are balanced using mercury columns.
Ensure that the valves have proper clearances before starting any fine tuning and that
plugs and wires are operating correctly. Instructions on performing a valve adjustment
can be found at http://www.ibmwr.org/rtech/r1100_valve_adjust.html
II. The Approach.
It is quite possible that a bike has both a surging (throttle plate screws and TPS) and a
vibration (throttle body) problem. With these instructions, you will address the surging
and vibration problems in that order. If you do not have a surging problem, DO NOT
adjust your TPS ! If you do not have a surging problem, DO NOT adjust your TPS ! If
you are not sure about your problem, then do not continue with these instructions and,
instead, balance the throttle bodies using "Throttle Body Balance for Dummies". In fact,
I strongly recommend that you balance the throttle bodies at least twice before you use
the instructions in this article. Throttle body balancing is relatively fast and easy to
accomplish and, you will need to balance the throttle bodies as part of setting the throttle
plate screws and TPS.
In addition to surge and vibration, some bikes will present an idle anomaly in which the
idle will be too high. The idle problem, which is nothing more than an idle in excess of
1200 rpm, occurs most frequently on GS and R models after resetting the throttle plate
screws and the TPS. This problem is addressed at the end of the TPS adjustment
instructions. Idle speed also is addressed in "Throttle Body Balance for Dummies" if you
are only performing a throttle body balance.
The basic knowledge about adjusting the TPS and basic throttle settings to obtain
optimal engine response is the work of Rob Lentini; his Zero=Zero article appeared in
MOA's Owners News and is on the IBMWR web site at http://www.ibmwr.org/tech.html.
This article does not present significant or new procedures, it has been written for
newbies and simply goes into greater detail. It was designed to help you find the right
63
part to tweak. These instructions assume that you know almost nothing about the bike,
where parts are located, or how it functions. The priority here is to help you diagnose
and adjust the bike, not engineering or theory. You may need detailed instructions the
first time you do the adjustment; subsequent adjustment will require much less
information. If you run into problems, contact the author by private eMail or at (305)255-
1010. For another perspective on setting the TPS, look at Rob Lentini's original work
which has already been cited.
III. How to set the TPS on the R850 and R1100
WARNING: BMW does not approve of this procedure. BMW warns that "The sealed
stop screws on the throttles must not be tampered with, or else the basic idle flow setting
will have to be reset by the manufacturer." There is a Throttle Position Sensor article by
Bob Gorman and an early Throttle Position Sensor article by Rob Lentini that present
ways to set the TPS without resetting the throttle stop screws. These do not violate the
BMW warning and these may be used before resorting to this procedure. The author of
this article assumes no liability for any damage or injury to you or your bike caused by
any errors or omissions.
Read through these instructions, and also "Throttle Body Balance for Dummies", before
you pick up a wrench or screwdriver. Find the parts before you start. This will save
work and cursing time.
Begin with a cold engine and do not start the engine until after the TPS has been
adjusted. Place bike on center stand with side stand retracted. You will need two
special tools, a digital volt meter (DVM) for setting the TPS, and a set of mercury
manometers (also called carb stix or mercury columns) for setting the throttle bodies.
12 Steps to Throttle Set Screw / TPS Adjustment
1. Loosen throttle cable (left side)
2. Loosen throttle body crossover synch cable (right side)
3. Back out the left throttle plate stop screw (underneath left side)
4. Attach DVM to red-white TPS wire #1 (rear) - ignition on
5. Move TPS to obtain zero reading (.006 volts) and lock TPS
6. Move left throttle plate stop screw to obtain .370 volts and lock screw
7. Large brass bypass screws in, bike on, warm engine, rough idle expected
8. Turn the large brass bypass screws out in 1/4 increments if bike will not idle; attach
carb stix
9. Set right throttle plate stop screw using carb stix
10 Reduce TPS in increments of 0.020 if idle exceeds 1100-1200 rpm
11. Reset throttle cable (left side) to .5 mm free play
12. Perform the "Throttle Body Synch for Dummies".
Each of the 12 steps above is explained below, with a detailed explanation of how to find
and adjust the correct part. All of the information on Step 1 will follow the Step 1
heading.
Step 1. Loosen throttle cable (left side)
Here are four (A-D) ways to find the throttle cable. Use all of these the first time you use
these instructions to ensure that you have the correct part.
64
(A) Starting at the front edge of the seat, if you were to hang a string onto the left side of
the bike, it would contact the black plastic air intake duct (2 1/4 inch diameter tube)
about 11 to 13 inches down. Follow this black plastic duct or tube forward to where it is
attached to a metal tube or duct that is 3 1/2 inches long with plastic and metal parts all
over it. Everything related to the TPS adjustment is attached to this metal duct, or a
similar metal duct in the right side. For our purposes, the metal duct has a top and
bottom area, an outside and an inside area (close to the body of the bike). There is a
bracket on the inside area where two cables are vertically attached. The cable closest to
the metal duct (forward outside) is the throttle cable.
(B) Starting at the rear of the large finned metal engine cylinder that sticks out on the left
side, the throttle cable is approximately two inches to the rear of this location and close
to the engine.
(C) The throttle cable can be generally located by first locating two plug-type wires on
the top of the metal duct, and from this point look down and between the metal duct and
the bike.
(D) There is an easily removable (and frequently lost or missing) three-sided plastic
cover with a round bottom that clips onto the top front area of the metal duct. This plastic
cover comes off by pulling it upward and toward the front of the bike. Take this plastic
cover off (no tools necessary) and the throttle cable is close to the location where the
inside of the plastic contacted the metal duct.
Now that you have located the general area of the throttle cable, by careful inspection
you will see that two cables come into the same area and mount on one metal bracket or
metal plate located on the inside area of metal duct. [On 1997 models there is one cable
only, the throttle cable. Disregard the references to other cables.] The cable that is the
furthest from the engine is the throttle cable (still forward outside). To make certain you
have the correct cable, move the throttle on the right handlebar and this should move the
throttle cable that you have identified on the left side. (You may need another person to
move the throttle on the right side of the bike while you watch the cable on the left side.)
If the left side cable does not move, you have not located the throttle cable. Move the
throttle on the handlebar and look on the left side for a moving cable that matches the
information above. Now check the cable next to the throttle cable by moving the choke
lever on the left handlebar and watch the choke cable move; do no loosen the choke
cable. There is a third cable to the rear of these two which is the crossover synch
cable; this is on its own mount and need not be loosened or adjusted in any way.
If you are not certain you have found the throttle cable, either find another BMW rider
with an R bike and ask for help finding it, or go pester your local mechanic.
This is a tight area in which to work and so you will remove the three-sided plastic cover
with the round bottom that mounts on the gas intake area. There are two plugs on top of
the metal duct that were covered by the three-side plastic piece you have removed;
these are fuel injection controls. The front plug of the two may be removed by
depressing (press in) on the wire clip on the plug and then lifting the plug from its
mounting. After removing both the three-sided plastic cover and the fuel injection plug,
there will be more room in which to work.
You are now ready to loosen the throttle cable, which was the whole purpose in finding
this cable. You must loosen the lock nut, the six-sided nut that sits on top of the bracket,
65
with a small wrench (counterclockwise). There is a metal piece that is threaded into the
lock nut which can now be loosed with your fingers by turning it in a clockwise direction.
Loosen the lock nut as needed so the cable is loose. Check this by twisting the throttle
on the handlebar; you must be able to give at least a 45-degree turn on the throttle and
see that the throttle cable is loose. Now depress (squeeze) the wire clip on the fuel
injection front plug and replace the plug you previously removed.
Step 2. Loosen throttle body crossover synch cable (right side)
After loosening the throttle cable, it's time to move on and to look at the right side of the
bike. Go to the same general area on the right side as you were examining on the left.
There are fewer controls and only one cable. Here are two ways (A, B) to find the right
crossover synch cable.
(A) There is a metal 2 1/4 inch diameter tube (similar to the left side but with fewer black
plastic or cable items attached to it) that also continues into the large finned cylinder (as
it does on the left side). There also may be a three-sided plastic guard with a round
bottom if you have an RS or R (not on the GS or RT, and not there if it has been lost).
From the metal tube area, look into the side of the bike to see a single cable mounted on
a metal bracket; it is the only cable in the area.
(B) The right crossover synch cable is located about two inches from the rear of the
large finned cylinder and close to the engine.
First remove the three-sided plastic cover with the round bottom if there is one. Next
loosen the lock nut that is located near the top of the bracket (turn counter clockwise).
After the lock nut is loose you can loosen the cable by screwing (clockwise) the metal
piece that is above the lock nut. Screw until the cable is loose. The loose cable can be
seen below the metal bracket.
Step 3. Back out the left throttle plate stop screw (underneath left side)
It's now time to return to the left side of the bike. When the throttle on the handlebar is
twisted, it not only moved the cable you have now loosened, it also moved a metal
flange piece that comes in contact with a metal plate. There are two ways to find this
metal flange piece and the left throttle plate area.
(A) Check instructions for Step 4 and find the TPS. If there were an imaginary line that
passed through the right TPS screw and then continued through the round metal body
on which the TPS is mounted, that line would intersect the left throttle plate stop screw.
When you move the throttle on the handlebar you also are moving the metal flange
piece that contacts the left throttle plate stop screw.
(B) The metal throttle flange is located near the inside of the metal 2 1/4-inch diameter
tube and is very low and near the inside of the tube. The easiest way to see this is to
put your head on the ground just forward of the rear tire and to look up. This is an
awkward position but the metal flange piece is easy to touch. The screw, that limits how
far it can close, is located on a metal plate above the flange. This screw determines the
distance between the flange and the throttle plate. [If you see an adjustment screw on a
long arm, this is related to the throttle advance (adjusts the "choke"); this is NOT the
screw you are looking for.]
Now that you have found the flange and screw, you now must figure out how to adjust
the screw. Loosen the silver metal clamp that secures the black plastic air intake hose to
the metal throttle body and rotate the clamp for a more unobstructed working area;
66
remove the hose if necessary. Remove (cut off) the plastic cable tie that secures a wire if
it obstructs the working area. Replace the cable tie, hose and clamp when finished with
the throttle plate screw adjustment. The physical manipulation that is described in the
next paragraph (especially on RS models) is a challenge to your stamina and will take
time, patience and any odd-ball tool that works. If you find a tool that makes this easy,
please please please contact this author with your hint.
Your job is to loosen the 10 mm lock nut (counterclockwise) using a small wrench, and
then loosen the 8 mm stop screw (counterclockwise) using a wrench or a screwdriver so
that the metal flange piece does not contact the screw at all. If you loosen the screw a
few turns you should be able to see a gap between the end of the screw and the metal
flange piece. You must see a gap, which means the left throttle is closed. There must
be a gap !
Step 4. Attach DVM to red-white TPS wire #1 (rear) - ignition on
The TPS is mounted on the outside of the left 2 1/4 inch metal tube you have been
working around; it is a black flat plastic cover that measures 2 1/2 inches wide x 2 inches
high with the word Bosch imprinted on it. This cover is attached by two allen-head
screws through the cover and the allen-head screws describe a horizontal line.
There is a prong attached to the bottom of the TPS, and a rubber boot that covers the
bottom of this prong. The prong can be removed easily by depressing the wire, which
acts like a latch, and pulling down. Do not remove the prong. Nothing bad will occur if
you do remove the prong from the body of the TPS, but for this adjustment the prong
must be attached.
The rubber boot that surrounds and protects the wiring that enters the bottom of the TPS
must be moved out of the way. Exert only enough force on the rubber boot to wiggle it
down far enough to expose about 1/2 inch of the four wires that enter the prong. The
wire furthest to the rear is coded; it is white and red and called wire #1. Insert a sewing
needle, a paper clip or other sharp and thin metal (electrical conducting) object up and
into the plastic housing where the white and red wire enters the prong.
Step 5. Move TPS to obtain zero reading (.006 volts) and lock TPS
Attach the ground probe (lead) of your digital volt meter (DVM ) to the spring of the side
stand or some other grounded metal object. Attach the other probe (lead) to the object
inserted into the white and red wire. With the bike on the center stand, with side stand
retracted, and with engine cut-off switch on the right handle bar indicating "on", turn the
ignition key to "on" but DO NOT start the bike.
Read the DVM and record this TPS value for possible future reference. Do not remove
the TPS screws; loosen them so that the TPS can be moved (adjusted). Turning the
TPS slightly in one direction will increase the voltage; turning it in the other direction will
decrease the voltage. Turn the TPS until the observed voltage decreases to about .006
or .005 volts, which probably is as low as the voltage will go. If it will go no lower, that's
okay. DO NOT continue to turn the TPS after it reaches its minimum value, which is
close to zero. Start at a high value (.300) and turn the TPS until it reaches the low value
(.006 or .005) and stop. [Note: Some digital voltmeters have an autorange function;
below a certain value they will read in millivolts. The .006 may read as 6 MV, which is
the same as .006 volts. Don't let the decimal places confuse you.]
Stop moving the TPS just when the voltage stops decreasing and lock it down there. At
this point we say the TPS is at zero. The throttle position is also at zero. The TPS is
67
now locked and set. This is the last TPS adjustment you will need; it is now set. You
will not change the position of the TPS again !! [Author's note: The throttle opening is at
zero and the TPS value is at zero, which explains Rob Lentini's title of "Zero-Zero" for
this procedure.]
Step 6. Move left throttle plate stop screw to obtain .370 volts and lock screw.
With the ignition still on, turn the left throttle plate stop screw clockwise (CW). By turning
the screw, the flange will be moved away from the throttle plate. Continue turning the
throttle plate stop screw until the voltage starts to rise, and continue until you reach 370
millivolts (.370 volts). Stop there, and lock it down with the lock nut. Blip the throttle
several times to check the accuracy and repeatability of the 370 millivolts. Readjust the
throttle plate screw if necessary. Remove the DVM, remove the object inserted into wire
#1, replace the rubber boot onto the TPS.
There is a possibility that .370 millivolts will not be the correct adjustment value for your
bike. This will be explained in Step 10.
Step 7. Large brass bypass screws in, bike on, warm engine, rough idle expected
On the right side of the bike, on the outer surface of the throttle body tube, is a large
brass bypass screw with a slotted (NOT Phillips) head that faces toward the rear of the
bike. If you were to place a screwdriver on the screw, the handle of the screwdriver
would point toward the right rear turn signal. This large brass bypass screw is
approximately one inch forward of the black plastic air intake tube. You are looking for it
on the right side because it is easier to locate there; there are fewer things in the way.
You can see the large brass bypass screws easily when standing near the turn signals.
If you look on the left side, you will find a similar large brass bypass screw. The official
BMW Repair Manual calls this a "recirculating air screw" at page 00.27.
Count and record the turns you make to lightly seat both the right and left large brass
bypass screws by turning them clockwise with a flat screwdriver.
Position a fan near the front tire with its output directed at the cylinders equally to avoid
overheating, or use two fans, one directed to each cylinder. If your bike has a Rider
Information Display (RID), allow the oil to heat up to 5 bars, otherwise idle the bike for
five minutes. It will idle rough because it is not in synch. Do not be concerned about a
rough idle at this time.
Step 8. Turn the large brass bypass screws out in 1/4 increments if bike will not idle;
attach carb stix
If the bike will not idle at all, back both large brass bypass screws out in increments of
1/4 turn until the bike will sustain a rough idle.
Secure the mercury manometers (carb stix) on the right side on the bike, where most of
the work will take place. Use any method that secures the carb stix (and the hazardous
mercury) vertically while the bike is running , such as hanging the carb stix from the
ceiling.
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.
68
Attach one of the carb stix's flexible plastic tubes to each brass nipple. Make certain that
the carb stix's plastic tubing does not touch hot exhaust parts; the tubing will melt. There
is no need to plug the black vapor recovery tubes.
Step 9. Set right throttle plate stop screw using carb stix.
At this time, locate the right throttle plate screw (mirror image position of the one on the
left side). The screw will have a lock nut similar to the one on the left side. If it is difficult
to manipulate the lock nut and screw, you have located the correct hardware.
With the bike warm and the fan on, look at the mercury columns. If they are not at an
equal level, loosen the lock nut on the right side throttle plate and adjust the screw in or
out until the mercury columns are equal. If the bike will not idle, then turn both large
brass bypass screws out another 1/4 turn.
Step 10. Reduce TPS in increments of 0.020 if idle exceeds 1100-1200 rpm
After adjusting the right side throttle plate screw to get equal mercury columns, look at
the rpm. Ideally, rpm is now 1100 to 1200. Some bikes will have an abnormally high
idle; as high as 1800 rpm or more. This is most prevalent in GS and R models. To
correct the high idle, return to Step 6 and place one lead of the digital volt meter (DVM)
back on the red and white wire of the TPS and ground the other lead. DO NOT move
the Bosch black TPS. Reset the left throttle plate screw (the left rear screw with lock nut
that was difficult to adjust) and reduce the TPS voltage by 0.020 volts (from .370 to .350)
by turning the throttle plate screw. Continue with the rest of the Steps in order after Step
6. If the idle is still too high, continue to reduce the TPS value by increments of 0.020
until the desired idle is reached.
Step 11. Reset throttle cable (left side) to .5 mm free play
Reset the left side throttle cable for about .5 mm of free play. Check this by twisting and
releasing the throttle several times and then rechecking the free play.
Step 12. Perform the "Throttle Body Synch for Dummies", which is part of the R1100
Maintenance Guide and also has been submitted for inclusion in the IBMWR Web site.
Copyright(c) 1997, Stephen Karlan (Dali Meeow) in Miami, FL. <dali@netrox.net>
69
Throttle Cable and “Choke” Cable Replacement, and Service of
the Cable Junction Block on a Late Model Oilheads - Bryan Lally
Bikes effected:
These instructions are for an R1100RS with the cable junction block (crank
wheel) throttle cable. It should be a very similar operation on any of the oilheads
except for the differences in fairings and trim parts. These instructions do not
apply to bikes with the crossover cable throttle arrangement.
Why did I do this?
The fast idle cable on my oilhead (at 3400 miles) started to "stick." When the fast
idle lever was moved from the normal position to the detent or start position, the
cable worked normally. But when the lever was returned to the normal running
position, the cable would go very slack and the throttle butterflies would not
return to the idle stops. Putting tension on the throttle cable would cause the fast
idle cable to snap back to its normal state (and the butterflies would close).
After some thought and considerable pulling and wiggling of cables, I decided I
needed to take a good look at the junction block assembly.
Short Story
The fast idle cable pulls on a small ramp, which pushes on a flat on the crank
wheel, turning the wheel and opening the throttle butterflies by way of two short
cables. The ramp acts like a wedge between the flat on the wheel and the slot
that the ramp slides in. There is a return spring for the fast idle ramp and cable
located at the junction block assembly. The ramp would not release from its
wedged position; it was being held in place by the tension supplied by the throttle
butterfly return springs through the short cables. As soon as the throttle handgrip
was turned, the ramp was released from contact with the crank wheel and
returned to its rest position by the fast idle cable return spring. The junction block
assembly was put together completely dry, with plastic sliding on plastic. A small
amount of grease was used to lubricate the ramp and the slot that it rides in; this
eliminated the clamping effect on the ramp and fixed the problem. In my opinion,
this should not have been assembled dry.
Replacing Throttle Cables on Junction Block (new style) Oilheads
Remove the seats.
Remove left and right fairing pieces.
Remove the air snorkel that feeds air to the air cleaner.
Remove the fuel injector covers.
Unplug the wires that trigger the fuel injectors at the injectors, or else they will be
in the way.
70
Remove the two screws that connect the upper fairing to the front of the gas
tank, and the two screws that connect the fairing insert pieces to the front of the
gas tank.
Remove the throttle cable from the twist grip (remove the small cover that the
cable goes into).
Remove the fast idle cable from the fast idle lever (pry off the "choke" cover, and
unscrew the large screw).
Remove the short throttle cables from the pulleys on the throttle bodies and
unscrew the adjusters from the throttle bodies.
Unplug the gas tank connector from the wiring harness, and remove the
connector from the tab on the frame.
Snip the cable ties that hold the fast idle cable and the throttle cable - there are
several.
Pull the right hand short throttle cable so it comes out _under_ the crankcase
ventilation hose. Remember when you put things back together that it goes
_over_ the hose.
Pull the throttle cable out also under the crankcase ventilation hose.
Note where the left side cables exit the bike.
Now remove the cable junction block. This is the small plastic piece that the
cables disappear in to. Removal is done from the right side of the bike. There is a
clip on the underside of the block, which must be held down while the block is
pulled out. I had to slightly bend the tab that holds the fuel tank electrical
connector up so that the cable junction block would clear it on the way out. Then
I was able to wiggle the cable junction block out underneath the crankcase
ventilation hose.
Note: the manual says to remove the engine block end of the crankcase
ventilation hose. I was able to leave this attached. The hose clamps are the use
once kind that require special pliers to replace, and there is very little room to use
a screw type hose clamp. Don't remove this hose unless you really have to. If
you have a tip here, I'd like to hear it.
With the cable junction block out, it should be clear how to replace the throttle
and fast idle cables.
The crank wheel is held in place with an E clip; remove the clip and you can take
the crank wheel out. Now you can clearly see the sliding ramp that needs
lubrication. Any kind of grease should work fine for this application.
Assembly is the reverse of disassembly (I always enjoy reading that). Don't forget
the cable ties. You will also have to do a complete throttle body sync when
you've got it all assembled. You should not have to readjust the TPS.
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Motronic Fault Codes - Stefan Hegnauer
Warning!: Although unlikely, it may be possible to screw up the Motronic. I take
no responsibility of any kind if you do so - in other words, it is your risk, and you
are on your own if something fails. If you are not absolutely sure you can handle
this, do not attempt this procedure!
Note 1: There is no connection of the Motronic (diagnostic unit) to any lights
Note 2: This is strictly for R1100R/RS/GS/RT, Motronic 2.2. I have no idea about
the Motronic 2.4 of the R1100S and R1150 family.
1. Get an analogue Voltmeter (digital ones are usually not fast enough, so you
could get wrong readings)
2. Hook it up between pin 1 of the diagnostic connector and ground (battery -,
chassis), switch ignition on (if you don't start or just very briefly turn the engine,
codes 1122 and 1133 will show, which is normal)
3. With a separate wire, connect the same pin 1 to ground for at least 5 seconds,
then remove the wire
4. The needle of the voltmeter should go to nearly zero for about 2.5 seconds,
then rise again to almost 12V
5. A series of short dips towards zero follows - count the number of dips
6. A short pause of 2.5 seconds follows
7. Steps 5 and 6 are repeated 3 times with perhaps different numbers of dips
8. You have now four counts, this is the Motronic diagnostic code (see table
below)
9. The whole sequence, beginning with the 2.5 seconds dip of 4 above, repeats
over and over until prompted again (step 3)
10. The next error code (if any) is shown after prompting
Example: one dip - pause - one dip - pause - two dips - pause – two dips - pause
- long dip - pause (repeat) => code 1122
Motronic Codes
0000 no further fault stored
1111 CO potentiometer
1122 Hall signal 1
1133 Hall signal 2
1215 Throttle butterfly angle sensor
1223 Engine temperature sensor
1224 Air temperature sensor
2341 Oxygen sensor at limit
2342 Oxygen sensor signal invalid
2343 mixture setting at limit
2344 Oxygen sensor shorted to ground
2345 Oxygen sensor shorted to 12V
4444 no fault stored
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To erase fault memory: pull fuse 5 for a few seconds.
Most of the information given above comes from the BMW booklet “BMW
Diagnose - Test Instructions Motronic”, # 01 71 9 789 901. This booklet is about
the K1100 but seems to be valid for the R1100 as well, at least in part.
One can get additional information for both Motronic and ABS - again, strictly for
the R1100 series with Motronic 2.2 and ABS II. Usual disclaimers apply.
Motronic Throttle Position Setting:
- same setup as for Motronic error codes (i.e. voltmeter or high impedance test
light on pin 1 of the diagnostic connector)
- switch ignition on
- connect pin 3 to ground and keep it grounded
- if the TPS is set correctly the voltage should read about 0V (check by twisting
the throttle slightly open - the voltage should rise to about 12V)
- rotate the pot if needed, recheck
- remove ground from pin 3
Note: make sure the 'choke' lever is not in action
ABS II:
- voltmeter on pin 2
- turn ignition on
- meter will indicate about 11V steady with no faults stored
- count eventual dips towards zero volts
- fix the cause of the fault and cancel code
ABS II Codes:
1 front pressure modulator
2 rear pressure modulator
3 front sensor
4 rear sensor
5 battery voltage low
6 ABS relay
7 ABS control unit
8 sensor gap front or rear
ABS II Canceling Error Codes:
this has been reported before. Just for reference:
- ground pin 2
- switch ignition on
- push ABS button for at least 8 seconds
- release ABS button
- switch ignition off and remove ground from pin 2
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Notes:
- I remember having seen a code 9 once, but cannot remember to what it
belongs
- ABS can store only one fault at a time
- codes 1 - 4 are latching, i.e. they don't go away automatically once the fault is
fixed
- codes 5 - 9 are self-canceling as soon as the ignition is switched off and on
again ( the fault does not persist!)
- the ABS output signal will need some filtering due to short spikes
Most of the information given above comes from the BMW booklet “BMW
Diagnose - Test Instructions for Antilock Braking System (ABS)”, # 0171 9 798
811 (5.90). The booklet is about the ABS I, but seems to be valid for the ABS II
as well.
LED Fault Code Reader – Henry de Kuijer
You can use an LED to read the fault codes mentioned in the write-up above.
Instead of blips on your meter, you will count LED flashes of light.
Here is the prototype: http://www.xs4all.nl/~hkuijer/jpg/Motronic/FrameSet.htm
The pictures will give you a good idea of the simple setup. The switch is to hook
pin 1 to ground for 5 sec. to start the diagnostic. The resistor is 2k2, on the high
side, but I don't know what the output of the motronic is. The best is, it works.
Analog Fault Code Reader – Rob Lentini
I finally got around to trying this out, and it works perfectly. Without turning or
starting the engine, I first got 1133. Then I reset per step 3 and got 1122. Final
reset and I got 0000, just as I should have.
If I did the procedure with the engine running, I got 4444 right from the get go.
I used a Fluke 79 DVM which has a fast-acting analog bar at the bottom of the
display.
In fact, it was so easy that I will start performing this on any bike I work on.
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R1100RS Driveshaft And Clutch Spline Lube - Kit Vercella
Editor’s Note: A spline lube is no longer listed by BMW as a regular maintenance
procedure on recent model bikes. If you have an early model R1100, you should
perhaps include a spline lube.
First a few introductory comments are in order. The following procedure is the result of
having done this particular service only once. It is certainly possible that those who have
more experience can offer some refinements to the procedure below; thus, making the
entire job more efficient.
This write-up is based on having done this service on a non-ABS 1993 R1100RS. If you
have a different model Oilhead and/or if your bike is ABS-equipped, the procedure may
be somewhat different.
If this is your first stab at this service, set aside AT LEAST ONE FULL DAY. You will
want to use the opportunity to clean and inspect various components that you won’t
have occasion to remove on a regular basis.
Be organized. Make notes and label parts if necessary.
I would recommend that you have access to a BMW shop manual, which not only
outlines this entire procedure, but provides the necessary torque values for reassembly
and offers a bit more detail to the steps below.
Before you begin, you will need a few things in addition to your basic tools:
12mm hex wrench socket
Loctite 243 (I used Loctite 271) threadlock
heat gun
(2) M8 X 1.25mm metric bolts (about 80-100mm long)
BMW lube #10 (or the substitute of your choice)
30mm socket
good music (no Bee Gees or Barry Manilow, please)
Okay, here we go.
Place the bike on the centerstand. As an ounce of prevention, tie the centerstand to the
front wheel. Although probably not necessary, I secured the front forks to the floor,
Remove the seat.
Remove the left and right side fairing panels.
Remove rear fender extension/license plate holder.
Remove rear wheel. (Be sure not to lose the spacer between the wheel and the rear
drive assembly).
Unbolt the rear brake caliper and tie it off to the rear footpeg assembly.
Remove the bolt that holds the strut to the rear drive.
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Loosen front hose clamp on the driveshaft housing boot and pull the boot loose from the
driveshaft housing. (Note: if oil pours out from the boot, plan on replacing either the rear
transmission seal or the oil seal in the rear drive unit).
The shop manual recommends draining the oil from the rear drive unit. However, if you
keep the rear drive unit upright after removal, draining isn’t necessary.
Remove rear bearing retaining bolts on the driveshaft housing. These are the two large
hex bolts located opposite one another on the driveshaft housing just forward of the
rubber boot. Since the bolt threads are covered with threadlock, it is necessary to heat
the bolts with a heat gun (BMW recommends to a maximum temperature of 120C). I
applied heat to each bolt for 4-5 minutes. Remove right bolt with a 12mm hex wrench
socket and a breaker bar (bolt is torqued to 105Nm). Remove the 30mm locknut on the
left bolt and then remove the left bolt. No muscle is necessary since this bolt is only
torqued to 7Nm.
Pull rear drive unit from driveshaft. Remember to keep rear drive upright if you didn’t
drain the oil.
Remove the two front bearing retaining bolts on the driveshaft housing. These bolts are
identical to the ones you just removed, but located opposite one another on the forward
part of the driveshaft housing. Follow same procedure.
Remove the shock absorber while supporting the driveshaft housing.
Pull the driveshaft housing off.
Pull the driveshaft from the transmission spline. Using a large screwdriver for leverage
worked well.
This is a good time to clean and inspect the splines on the driveshaft, rear drive unit, and
the rear of the transmission. Check the U-joints for excessive play. Also, check the four
needle bearings and their races in the driveshaft housing. Be sure that they are
sufficiently greased.
So far so good? Have a sandwich and change the audio tape or CD. Remember: no Bee
Gees or Manilow.
Next you need to remove the transmission in order to be able to clean and lube the
clutch splines. But, unfortunately you have to strip more stuff off of your bike.
Remove the fuel tank. See Jon Diaz’s fuel filter change instructions if you haven’t done
this before.
Remove battery.
Unplug the electrical connector for the air temperature sensor on the air box cover.
Remove air box cover & air intake snorkel.
Remove the four nuts holding down the battery tray.
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Remove the three screws which secure the air box assembly. One screw is located at
the rear of the air box and one screw on each side near the front of the air box. Later you
will remove the air box assembly itself.
Disconnect the breather hose from the air box and the wire harness that fits into a slot at
the front of the air box.
Remove the rear brake fluid reservoir from its bracket.
Remove the rear brake line from its bracket.
Unplug the connector for the brake light switch located near the rear brake fluid
reservoir.
I don’t recall if it was necessary, but I removed the right front footpeg assembly.
Unplug the connector for the oxygen sensor on the exhaust pipe.
Remove the bolt holding the muffler to the left rear footpeg assembly.
Unbolt and remove the muffler. Check the two rubber mounts for the muffler. In the past
three years, I have discovered three broken mounts. (I think they are about $8 apiece).
Right about now you are seriously wondering whether you will ever get your beloved
bike back together again. Fear not. Just continue to be organized and methodical. If you
are so inclined, consider the power of prayer :-) .
Remove the two bolts that hold the rear frame assembly to the transmission.
Loosen the two bolts at the front of the rear frame assembly These are the pivot points
when the rear frame is to be tilted upward.
Remove the long bolt at the rear of the struts which attach near the steering head.
Disconnect the clutch cable from the transmission.
Remove the plastic cover from the starter and remove the starter itself. If I recall, you will
have to disconnect the wire for the sidestand neutral switch. (I had disabled this switch
years ago).
Now unless I have forgotten something, you are just about ready to tilt the rear frame
assembly upward in order to remove the transmission. But first make sure that any
wires, hoses, or cables won’t be pinched or stretched when the frame is tilted. You might
have to cut a few zip ties to prevent this. Pay particular attention to the throttle and
“choke” cables. I didn’t and apparently stretched the suckers. This required that I
readjusted and re-synched the throttle bodies after reassembly.
Loosen the hose clamps holding the air intake tubes to the throttle bodies and pull the
intake tubes loose.
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At this point I don’t recall whether I was able to remove the air box assembly, or whether
the rear frame had to be partially tilted upward first. (Hey, remember I only did this once).
But, it should be obvious to you once you have reached this point.
Unless I have forgotten something, you’re now ready to lift the rear frame. You can
either tilt the rear frame upward and connect it with a strap to the handlebars or, as I did,
suspend the frame from the ceiling. Either way, you are simply making room to slide out
the transmission.
Disconnect the two electrical wires (oil pressure sensor?) coming from the rear of the
transmission. If you remove the sensor itself, expect some transmission fluid to leak out.
There are six bolts holding the transmission to the engine. First remove the bolts in the
upper left corner and the lower right corner. In their place screw in BMW mandrels (part
#23 1 280) or make your own mandrels from two M8 X 1.25mm bolts. I bought two hex
bolts 100mm long & cut the heads off. By screwing these into the bolt holes, the
mandrels serve as a guide on which to slide the transmission out & to reinstall it.
Remove the remaining transmission bolts and slide the transmission out.
Well, you did it. Now grab a camera & take a picture of whatever is left standing of your
pride and joy.
Thoroughly clean and inspect the clutch splines on the transmission. Lube the clutch and
driveshaft splines with BMW lube #10 (or the substitute of your choice). Don’t over lube
the clutch splines.
Before refitting the transmission, you might want to inspect your clutch.
Now reassemble everything in reverse order. No, don’t reassemble everything
backwards; reassemble everything in the reverse order of how you removed it. :-)
When refitting the bearing retainer bolts into the driveshaft housing, remember to apply a
thin coat of threadlock to the threads. Then torque to specs. Be methodical, make sure
that everything fits properly and torque all fasteners to specs. If you didn’t have any
serious difficulty up to this point, you shouldn’t have any problem the rest of the way.
After everything is finally buttoned down, hold your breath, fire up the bike and go for a
test ride. Park bike, scream like Ed McMahon just gave you one of those 4-foot
$10,000,000 checks, and slam a well-deserved beer.
See ya back here in another 40,000 miles.
(continued on next page)
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A few torque values:
fixed bearing retainer bolts (on right side of driveshaft housing) 150 Nm(105?)
idler bearing retainer bolts (on left side of driveshaft housing) 7 Nm
locknut on idler bearing retainer bolts 105 Nm
transmission to engine case bolts 22 Nm
brake caliper bolts 40 Nm
shock absorber bolts (RS 8.8 screw) 43 Nm
(RS 10.9 screw, GS,R,RT) 50 Nm
strut to rear drive 43 Nm
long bolt connecting struts to frame 47 Nm
rear wheel lug nuts initial: 50Nm/final: 105Nm
rear frame to transmission 47 Nm
A few torque values:
fixed bearing retainer bolts (on right side of driveshaft housing) 105Nm
idler bearing retainer bolts(on left side of driveshaft housing) 7Nm
locknut on ilder bearing retainer bolts 105Nm
transmission to engine case bolts 22Nm
brake caliper bolts 40Nm
shock absorber bolts 43Nm
strut to rear drive 43Nm
long bolt connecting struts to frame 47Nm
rear wheel lug nuts initial: 50Nm/final: 105Nm
rear frame to transmission 47Nm
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Super Tuning!
"Zero = Zero" Method for Adjusting BMW Oilhead Throttle
Position Sensor To Reduce or Eliminate Engine Surging - Rob
Lentini
Need:
Many BMW R259 "Oilhead" Boxers surge at constant throttle settings and low to
moderate speeds. Precise adjustment of the Throttle Position Sensor (TPS), one
of the two most important input sensors of the Motronic fuel injection system, is
critical in reducing or eliminating surging.
History:
Since 1994, BMW and dealer service personnel have not totally satisfied their
customers in solving this problem. At least one factory "service bulletin" has
addressed this issue with mixed results.
Caveat:
Performing the following procedure is not BMW approved and may void the
warranty if a failure has a "causal" relationship with this non-approved procedure.
Prerequisite:
Performer should be a reasonably skilled mechanic with knowledge of Motronic
fuel injection theory of operation. He/she needs a quality Digital Voltmeter, a
mercury or electronic manometer and common tools . All scheduled maintenance
should be performed prior to this procedure. Specifically, ignition timing, spark
plugs, valve clearances, Motronic coding plug and checking for throttle housing
inlet manifold air leaks should be performed per BMW procedures. On rare
occasions, the main electrical harness has also been at fault. ALL warranty
procedures should be requested, performed and documented on a warranty-
covered motorcycle prior to attempting this adjustment. The following should be
performed only after there is NO warranty recourse left or warranty in effect.
Doing this procedure could be at your own risk.
Note:
"Oilhead" BMW spark plugs are Bosch FR6DDC of dual "side electrode"
configuration. The author has found that standard "over the center electrode"
plugs, specifically Autolite 3923, contribute to smoother running and less surge.
Simply replacing the OEM Bosch plugs with the Autolite 3923 gapped to .028"
could solve some surging and obviate the need for TPS adjustment. Change
from non-BMW plugs at your own risk. And....
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IF YOU HAVE NO COMPLAINTS WITH YOUR BIKE, LEAVE IT ALONE!
Procedure (reference BMW or Haynes manual for location of components):
1. Generously loosen the free play at the throttle cables to both left and right
throttle bodies (note '96 and newer "Oilheads" have a different throttle cable
mechanism--see manuals)
2. Unscrew the left throttle body throttle stop screw (under and inside of the
throttle body) counterclockwise (CCW) about three turns or until you can see a
gap between the end of the stop screw and the flange it pushes on to open the
throttle. You are now assured the left throttle is FULLY closed. This is important!
("Zero" throttle opening).
3. Attach the Digital Voltmeter (DVM) black lead to frame ground and the red
lead to the red/white wire going to the TPS connector located on the left cylinder
throttle body. The TPS is a black plastic 2" by 2" square module with a connector
on the bottom. Gently pulling the rubber connector boot down will expose the four
wires entering the connector to the TPS. Probing and pushing up with a paper
clip is one method of reaching the red/white wire's contacts. Put the DVM red
lead on the paper clip, turn on the ignition and engine cutoff switch, and retract
the sidestand. You should see an indication on the DVM near zero. Be SURE
you are on the DC Volts selection.
4. Loosen the two Allen head screws securing the TPS. Adjust the TPS by slowly
turning it within its slots until the observed voltage decreases to about .006 DC
volts. It will probably go no lower, which is OK. DO NOT turn it any more as the
wiper of the pot has already reached the end of electrical travel. Stop turning the
TPS just when the voltage stops decreasing and then turn it in the opposite
direction to increase the DVM by .004. Lock it down there. Going slightly up by
.004 volts will ensure your are not going "below" zero volts and this will typically
result in a "zero" value of .010 volts. Be careful of DVMs which "autorange" and
can confuse readings! ("Zero" TPS voltage .006 +.004 volts = .010)
5. With "Zero = Zero" set (zero throttle plate opening and zero voltage), turn the
left throttle body stop screw clockwise (CW) until the voltage starts to rise.
Continue turning until you reach .370 - .400 volts, the voltage the BMW analyzer
looks for the TPS at idle to cause a digital signal to "flop" or change symbology.
Lock down the stop screw with the jam nut if so equipped (early units are an
interference fit). Blip the throttle several times to check accuracy and repeatability
of the voltage to be within .370 - .400 volts. Readjust the stopscrew (not TPS
Allen screws!) if needed. Following this, reset the left throttle cable free play to
.5mm. Now you are forever done with the TPS adjustment.
6. Connect the mercury or electronic manometer to both throttle bodies. Prior to
starting the engine, use a common screwdriver to lightly close both rear-facing
brass air bypass screws on the throttle bodies, then open them to:
R1100 RS/RT: 1 1/2 turns from closed
R1100 GS/R: 2 1/4 turns from closed
R850R: 2 1/4 turns from closed
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Start and warm up the engine to get 5 bars on the RID oil temperature if so
equipped. Idle will be rough due to the need to synchronize left to right throttle
bodies. Use a big rear-facing fan from the front of the bike to control cooling, if
required.
7. After warm up, LEAVE THE LEFT STOP SCREW ALONE! (The one used to
set .370- .400 volts). Adjust the right throttle body stop screw to get perfectly
equal mercury in both columns or electronic indication.
8. Adjust the right throttle body cable for equal mercury readings at just off idle,
around 1500 RPM. Use the throttle to increase RPM, not the "choke" start lever
when synching.
9. Finally, adjust both brass bypass screws individually or together in conjunction
with the manometer to yield a proper idle speed of 1000-1100 rpm and equal
mercury or vacuum readings. Closing the bypass screws will decrease RPM;
converse for opening them. On rare occasions where proper idle speed cannot
be set with the bypass screws, return to step 5 and incrementally increase or
decrease the stop screw voltage from the .370 - .400 setting then repeat
subsequent steps. Raising the stop screw voltage will increase idle RPM and
decreasing it will lower idle RPM.
10. Inspect your work and test ride, perhaps re-performing synch using ONLY the
bypass screws and right throttle cable to "fine tune."
Summary:
The TPS was set for zero volts at zero throttle plate opening (+.004 volts to
assure not going "low"). Then the left throttle body TPS was set using the stop
screw to .370 - .400 volts followed by an accurate synch of the right throttle body.
Results:
This is a simple procedure and it has worked on countless "Oilhead" BMWs. You
will notice good throttle response, best possible fuel consumption, little if any
surging and good top end. Properly performed, emissions are unaffected if not
improved.
Advanced Ignition Timing - Rob Lentini
Most manufacturers set the ignition timing for the typical vehicle with poor fuel
quality in mind. Modest performance gains may be achieved by REASONABLE
increases in initial advance. Just like my K75S, the R1100 is no exception.
Assuming you are NOT experiencing ANY pinging or detonation, you can easily
advance the ignition timing by about 3 degrees. Here's how to do it:
- Remove the small rubber timing hole cover on the clutch bellhousing (just inside
the right throttle body).
- Remove the black cover on the front of the engine. This covers the alternator
drive pulleys/belt.
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- Notice on the lower (crankshaft) pulley that the three timing plate securing
screws are exposed, and that the timing plate (which the Hall transmitters are
mounted on) can slide CW and CCW in three slotted holes.
- Put the tranny in 5th gear and, while observing the flywheel with a good
flashlight, move the rear wheel to rotate the engine. You will be looking for "OT"
(top dead center), "Z" (full advance) and "S" (the 6 degree initial advance mark).
- Warm the engine and observe, with a timing light, where initial advance is
taking place. With the engine at 1000 RPM or less, the advance will be very
close to "S". Turn off the motor, loosen the three screws holding the Hall
transmitter plate, and tap the plate in a CCW direction from the front to the end of
slot travel. Tighten down the three screws and recheck the timing. Be SURE the
idle RPM is 1000 or less! If your R1100 is like mine, the timing will be advanced
50% further than the "OT" to "S" mark, for about 9 degrees of initial advance. If
so, put everything back together and, if during your test ride you detect no
noticeable detonation, you are in business. I recommend only Premium fuel if
the ignition is advanced. Never use less than the BMW-recommended Mid
grade fuel if the ignition is not advanced.
Valve Lash Increase - Rob Lentini
If you are like me, try this. I like low and mid-range driveability and throttle
response. My R1100RS would not idle for several minutes on cold mornings
until I increased valve lash. Increasing valve lash FIXED the problem, and I've
lost no discernible top-end power. Increased valve lash is equivalent to closing
the valves sooner--"milding" the cam timing.
Set the valves COLD from/to:
Intake: Spec: .006" to: .012"
Exhaust: Spec: .012" to: .014"
Your idle will be MUCH smoother and throttle response immediate but
controllable. Increase in valve noise is minimal. Valves will run cooler.
Results of Increased Valve Lash and Advanced Timing - Rob
Lentini
The following results were obtained from several runs on a dyno with my 1994
R1100RS:
1. Advanced timing (9 degrees) results in a 2 - 4 horsepower increase across
the entire RPM range. The 4 horsepower increase was in the meat of the power
band, from 6000 RPM and up. There was no detonation.
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2. The average torque and horsepower, across the entire 4th gear roll-on range,
3500 - 7500 RPM, was improved by increased valve lash.
2. Increased valve lash and advanced timing (9 degrees) netted an average
torque increase of 3.1 and an average horsepower increase of 4 over
stock valve lash and stock timing (6 degrees).
Non-OEM (Original Equipment Manufacturer) Plugs for the
R1100/850 Oilhead - Rob Lentini
The BMW Internet lists have been ablaze lately over spark plugs! Why has a
simple item been such a popular subject of discussion? Here’s why…
Many of you are aware (sadly so!) of the surging that is common in many of the
R1100/850 series BMW Oilheads. This subject itself has been one of much
discussion and I took some time to investigate it myself on my personal ’94
R1100RS. My work led to my four part series on “R1100 Fuel
Injection/Surging/Fixes”, and later my “Zero=Zero” effort on getting the Throttle
Position Sensor (TPS) optimized for best performance. However, along the way
in doing this I learned that spark plug performance and selection can play an
important part in overall performance of the R259 Boxer.
Being a thrifty person (a nice way of saying “cheap”!), I have habitually looked for
aftermarket service item parts that meet or exceed OEM requirements but are
more readily available and less expensive. Wear items like brake pads, oil filters,
air filters, and spark plugs are open-discussion items for me and it wasn’t long
after my Dec ’95 purchase of a used ’94 R1100RS that I began the process that
had ended with the sale of my ’87 K75S.
I’d had good luck with Autolite 4153 plugs in my K and I was eager to avoid the
extravagant price of the OEM Bosch plugs of about $10 fame. So armed with my
Autolite and Champion spark plug catalogs, I cross-referenced to the point of the
best possible match: Autolite 3923 and Champion RC9YC plugs. But wait;
here’s the difference.
The ‘94-spec OEM Bosch plugs for the R1100RS are FR5DTC, a unique three
ground electrode setup that surrounds the center electrode from the side. The
Autolite 3923 and the equivalent Champion RC9YC plugs are standard single
ground electrode “over” the center electrode as many of us are familiar with.
Would these “standard” plugs work?
I took the dive, bought Autolite 3923s, set the gap to the BMW specification of
.031” or .8mm, and went for a ride. They worked great! I even noticed smoother
power characteristics and somewhat less surging, and this was in early ’96
before I began my above-mentioned Injection/TPS experiments in earnest. So
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you see, I’ve been using non-OEM plugs in my oilhead since about March 1996
(about 28K miles) with TOTAL success.
By the way, BMW changed their own plug spec to a two-electrode variety in July
1996 under the auspices of the “Low Friction Throttle Cable” service bulletin
#2748 which was an attempt to solve the surging I was investigating at that time.
In so doing, BMW revised the specified plug to the two-electrode Bosch
FR6DDC, a slightly hotter running tip. Some have reported the newer Bosch
plug is an improvement, but many other riders I have communicated with say the
Autolite or Champion plug is, in most cases, quite superior in operation and
surging minimization.
What’s my favorite? Autolite. They exhibit minimal wear during the 12,000 mile
specified service life and the center electrode color (on my RS) is a perfect
medium to light tan on the insulator. My experience with Champions (in K-bikes)
is satisfactory--quite good actually--but the Autolites seem to win out in life
expectancy, electrode wear, and have a performance edge that I “think” I can
feel. Perhaps this is just a prejudice, though.
Some riders have reported that the non-OEM Autolites or Champions are 1/8”
longer than the original Bosch plugs. I don’t find this to be the case with the
Autolites. The measured length from the crushed gasket to the tip of the
electrode is 22.5mm on the original 3-electrode FR5DTC and 23mm on the
Autolite 3923. Perhaps the length of the FR6DDC is slightly shorter and/or the
Champion RC9YC is slightly longer equating to the reported difference. I haven’t
measured the Champion, but in any case there have been no reported
interference problems and all of these plugs are 14mm, ¾” reach and take a 5/8”
socket. Use a 12 point thinwall socket to clear the small cylinder head access
hole.
So here are your options, gapped at .031” or .8mm:
OEM:
Bosch FR5DTC (3-electrode)
Bosch FR6DDC (2-electrode)
Non-EOM:
Autolite 3923 (1-electrode)
Champion RC9YC or RC9YC4 (1-electrode)
(Note: If you are hard-core Bosch, their 1-electrode Autolite 3923 equivalent is
the F6DC)
One VERY good thing about these non-OEM plugs is their availability and price.
For example, you can purchase the Autolites at a store such as Auto Zone or
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Checker for about $1.20 each and then get a $.50 rebate each on top of that.
What a deal for better performance!
86
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 shaft
bushings and/or seals. While these parts are not currently available for
replacement (though may be shortly), here's how to tell if you have this rare wear
problem:
Spray carb cleaner, propane, or simply WD-40 at the throttle shaft pivot area with
the engine running and listen for RPM speed-up. These bushings/seals are
located just outside of the cable wheels on each throttle body—the arcing
grooved wheel that encloses the throttle cable for each cylinder throttle body.
The area to be sprayed is between the surface of the cable wheel and the
throttle body casting. When spraying, avoid the intake of the air box "horn" on
the left side of the engine or you may get false RPM increases from inhalation of
the solvent into the air box.
A speed-up indicates the solvent is being "vacuumed" past a bad bushing and/or
seal and is being pulled into the cylinder as more "fuel." Try this procedure at
idle and at, say, 3000 RPM to pick up rotational differences of the throttle shafts.
If you detect RPM increase you have little recourse other than a warranty claim
or throttle body replacement at your expense. Subsequent parts availability may
soften this expense in the future.
Editor’s Note: You might also experience an increase in RPM if you have an air
leak at the large hose clamps - front and back of the throttle bodies (especially
the front clamp). So avoid spraying there when checking the butterfly seal or
better yet, check them by spraying before you do the above procedure and
tighten the hose clamps if necessary.
87
GS Intake Manifolds and Cat Code Plug “Hop Up” An
R1100RS/RT! - Rob Lentini
Many BMW “Oilhead” riders spend big bucks chasing more horsepower with
expensive exhaust systems, magic Motronic microchips, even camshaft and
head modifications. I’ve wondered whether many of these riders have defined
what it is they want to “improve”?
I don’t know about you, but absolute high RPM power is NOT why I purchased a
BMW. Superior broad torque, “user friendly” power delivery and fuel economy is
what I seek in an engine. Top speed advocates often perform expensive
modifications to a BMW for only a modest peak horsepower increase. Then the
machine may be less rideable and reliable on the street. Not my style, thank
you! I prefer strong roll-on power for normal every day commuting, sport riding
and touring.
When I learned about a simple way of getting almost 5 more peak mid-range
horsepower from my ’94 R1100RS while increasing and smoothing power
delivery from 3000 to 6500 RPM for less than $35, I was all ears! Here are the
facts…
Anthonie Mans posted an interesting test on the Internet BMW Riders/Oilheads
lists performed by “Das Motorrad”, a Euro motorcycle magazine. All that was
done to a stock R1100RS (same engine as in the RT) was to give it a
dynamometer baseline run and then replace the intake manifolds (black tubes
connecting the airbox to the throttle body intakes) with those from a GS. Then
they dyno’d the RS again. Here were their reported results in Newton Meters of
Torque and Metric Horsepower:
RPM Torque (GS tubes) Torque (RS tubes) HP (GS tubes) HP (RS tubes)
2000 86 87 24 25
2500 85 86 29 30
3000 92 89 41 39
3500 90 89 44 43
4000 92 83 52 47
4500 96 96 62 62
5000 102 99 73 72
5500 106 102 82 80
6000 101 96 86 81
6500 92 92 87 87
7000 86 91 86 90
7500 79 85 84 90
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If you plot these torque and horsepower curves you will notice a much smoother
power delivery across the RPM range and an average power increase of 2.28
horsepower from 3000 to 6000 RPM – right in the meat of where most of us ride.
But would the dyno results pan out on the road? I purchased and installed a set
of these manifolds to find out.
Part numbers and cost for the GS tubes (manifolds) are:
Left: 13 71 1 341 405 $13.99
Right: 13 71 1 341 406 $19.40
A reasonable sum, I’d say!
The GS manifolds are 247 mm long and have a 47 mm inside diameter. They
are MUCH longer than the RS variety which measure 127 mm and have a 51
mm inside diameter. You can’t confuse them!
To install the new tubes you will find it easiest to remove the throttle bodies from
the rubber cylinder head intake spigots. Loosen the two clamps that secure each
end of the RS intake tubes and then loosen the spigot clamp. Push the
tube/throttle body assembly slightly into the air box to achieve separation of the
throttle body from the spigot. It’s now easy to separate the throttle bodies from
the intake tubes and replace the tubes with the GS types. Be careful to align the
non-symmetrical GS tubes with their casting indices aligned up and down with
the throttle body casting marks. The GS tubes are also (as the part numbers
indicate) different for left and right as opposed to the identical RS tubes, which
may be interchanged. Reinstall the throttle bodies into the spigots, observing the
index “tang” alignment. Double check the tightness of all six clamps you
loosened to do the installation. Following installation, perform normal throttle
body synchronization though the adjustment may hardly change. By the way,
this modification will not affect “Zero=Zero” adjustment of the Throttle Position
Sensor if previously performed (re: “Bench Wrenching”, BMW Owners News,
May 1997).
So how does this $35 “hop-up” perform? Here are the plusses and minuses:
First, Jon Diaz (who performed the mod to back up my data)…
“Rode to work today. Bike seems livelier from idle to 5K......really seems to jump
up off the bottom. One big thing I noticed was the increase in intake noise....even
with earplugs in, its a lot louder.”
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My take, after an initial 500 miles of testing…
Plusses:
- Improved roll-on power.
- Engine revs more quickly.
- Bike accelerates in the next higher gear almost like it did with the RS
manifolds in the next lower gear.
- Overall gearing now seems “shorter” (lower) when matched with the
increased low RPM torque.
- Average power delivery is smoother and stronger from idle to red line.
- Marginally less fuel consumption (at steady speeds).
- The bike is easier to ride!
Minuses:
- Increased intake noise (honk) from the longer length tubes. (resonance). GS
riders won’t notice this since it must be identical to GSs.
- Top end is reduced by about 4 MPH.
- Acceleration from 6500 RPM in 5th gear to top speed is reduced from RS
levels.
But wait, the story is not over! If the GS intake manifolds worked so well, how
effectively would fuel injection reprogramming optimize the system even more?
Having experimented with the Motronic fuel injection on my RS, I knew there
were six different “maps” stored in the computer which are activated by different
“Cat Code Plugs.” So, to complete the GS intake “clothes” makeover, I replaced
the RS yellow Cat Code Plug with the GS pink unit. This connects different
coding plug terminals and activates the GS map instead of the RS’. The coding
plug is located in the electrical box under the seat, one row forward of the fuses.
Look in your owner’s manual for reference. If you replace (or even temporarily
remove) the coding plug, you should uninstall the 5th fuse from the left of the fuse
bay for a few seconds and then reinstall it to reset the injection memory and clear
any “faults.”
Part number and cost for the GS Cat Code Plug is:
61 36 8 366 625 $5.99
So, how did BOTH the GS manifolds and coding plug, all for ONLY $39.38, work
in my RS? To find out I went on a 580 mile loop from Tucson through the
Arizona high country, a varied ride that encompassed Tucson’s 2600 feet altitude
all the way to the “Rim Country” at 9200 feet. This route is along the famous
“Coronado Trail”, US 191 (formerly US 666), and it was a superb workout of low
and high speed cornering, accelerating, and trailing throttle, especially coming
back home to Tucson through the Salt River Canyon. Verdict?
90
I was very pleased with the improvement in throttle response, low and mid range
power, and about a 5-10% increase in fuel economy! I noted smaller throttle
openings for a given cruising speed and a complete lack of backfiring that my RS
had always suffered from with the Staintune “touring” system I have installed.
With smaller throttle openings for a given load, accurate throttle body synch
adjustment will be more important. Nonetheless, I was delighted with the results!
In summary, I think the GS intake manifolds with GS Cat Code Plug is an
effective and inexpensive modification that will give an RS/RT more “grunt”
where most riders need it, with little top end sacrifice. Heck, do most of us really
need increased performance above 6500 RPM (120 MPH+)? That’s where the
above reported horsepower figures intersect. I’ll settle for “real world” roll-on
improvements with inexpensive BMW parts!
Note: The GS Cat Code Plug can, in some instances, cause hard starting and
cold running problems in some RT’s and RS’s. If this is the case on your bike,
simply revert to the standard Yellow Cat Code Plug. Most of the performance
benefits from this modification are derived from the intake manifolds.

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