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Manual Details
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Coverage Areas
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Supported Models:
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BMW R80, R90, R100 series motorcycles
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Supported Years:
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1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996
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Page Count
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Estimated Pages:
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700-1000 (typical for comprehensive WSMs of this era, actual may vary)
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Manual Type
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Type:
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Workshop Service Manual (WSM)
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Language
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Language:
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English
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Format
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Format:
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Digital (PDF)
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Manual Coverage
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Systems Covered
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Engine:
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Complete disassembly, assembly, overhaul, diagnostics, troubleshooting of air-cooled boxer twin engines (e.g., R80, R90/6, R100/7, R100RS, R100RT, R100GS, R100R)
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Transmission:
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5-speed gearbox: removal, disassembly, reassembly, lubrication, troubleshooting, common wear parts
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Drivetrain:
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Clutch (single dry plate), driveshaft, bevel gear drive unit: maintenance, inspection, repair
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Fuel System:
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Carburetor (Bing 32/40/48mm) overhaul, adjustment, synchronization; fuel tank maintenance, fuel lines
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Ignition System:
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Electronic ignition systems (breakerless), ignition timing, component testing, spark plugs
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Electrical System:
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Wiring diagrams, charging system (alternator, regulator), battery maintenance, lighting, starter motor, horn, instrumentation
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Brakes:
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Front and rear brake systems (disc and drum), hydraulic systems, fluid replacement, bleeding, caliper/master cylinder overhaul
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Suspension:
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Front telescopic forks (e.g., /7 series, Monolever, Paralever), rear swingarm, shock absorbers: maintenance, fluid changes, seal replacement, adjustment
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Wheels Tires:
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Wheel bearing maintenance, tire inspection and replacement, spoke wheel care
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Frame Chassis:
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Frame inspection, headstock bearing maintenance, general chassis integrity
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Bodywork:
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Fairings (e.g., RS, RT models), fuel tank, seat, fenders: removal, installation, minor repair considerations
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Procedures Included
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Scheduled Maintenance:
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Oil changes, filter replacements, valve clearance adjustment, spark plug replacement, drive shaft lubrication, brake checks, tire pressure checks
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Troubleshooting:
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Diagnostic charts for common running issues, electrical faults, starting problems, braking issues
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Engine Rebuild:
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Piston removal/installation, cylinder honing, crankshaft inspection, bearing replacement, gasket renewal
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Electrical Diagnostics:
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Testing stator coils, regulator, ignition module, starter solenoid, wiring harness continuity
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Carburetor Tuning:
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Synchronization of dual carburetors, idle speed and mixture adjustment
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Brake System Overhaul:
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Seal replacement in master cylinders and calipers, brake line flushing and bleeding procedures
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Suspension Servicing:
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Fork oil replacement, seal head replacement, rear shock absorber inspection and replacement
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Technical Depth
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Depth:
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Comprehensive, suitable for home mechanics and professional technicians. Includes detailed step-by-step instructions, exploded diagrams, torque specifications, and diagnostic procedures.
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Engine Specifications
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Primary Engine
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Engine Type:
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Air-cooled, four-stroke, horizontally opposed twin-cylinder (Boxer)
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Bore X Stroke:
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Varies by model (e.g., R80: 82.5mm x 74.5mm; R100: 94mm x 70.7mm)
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Displacement:
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Typically 798cc (R80), 971cc-999cc (R90/R100 variants)
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Compression Ratio:
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Varies by model (e.g., 8.5:1 to 9.5:1)
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Valve Train:
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OHV, two valves per cylinder, pushrod actuated
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Cooling System:
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Air-cooled
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Performance
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Horsepower:
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Varies by model (e.g., R80: ~50-55 hp; R100: ~65-70 hp)
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Torque:
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Varies by model (e.g., R80: ~60 Nm; R100: ~75 Nm)
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Fuel System
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Carburetors:
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Typically dual Bing constant-velocity carburetors (e.g., Bing 32/40/48mm)
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Fuel Type:
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Unleaded gasoline (91 RON or higher, though leaded was common in earlier years)
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 5,000 - 10,000 km or annually. Manual specifies exact interval and oil type.
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Valve Adjustment Interval:
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Every 10,000 - 20,000 km. Critical for performance and longevity.
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Transmission Oil Change:
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Typically every 20,000 - 40,000 km. Manual specifies interval and lubricant grade.
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Fluid Specifications
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Engine Oil Type:
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API SG, SAE 20W-50 or 15W-50 recommended (check manual for specific recommendations based on climate).
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Brake Fluid Type:
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DOT 4 (or DOT 3 for older systems if specified). Regular flushing is crucial.
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Fork Oil Type:
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Type F automatic transmission fluid or specific motorcycle fork oil, with appropriate viscosity grade (e.g., SAE 5W or 10W).
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Known Issues
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Common Wear Items:
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Valve guide wear, clutch wear, output shaft seal leaks, aging electrical connectors, output shaft splines (lubrication critical), starter clutch issues, swingarm bearing wear.
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Electrical Gremlins:
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Corrosion in wiring connectors, particularly around the ignition switch and rectifier wiring. Diode board issues on older models.
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Engine Mounts:
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Rubber engine mounts can degrade over time, affecting vibration isolation.
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Vehicle History
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Brand Heritage
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Bmw Motorcycle Legacy:
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BMW has a long history of producing reliable and innovative motorcycles, particularly known for their boxer engines and shaft drive.
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Model Evolution
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R Series Development:
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The R80, R90, and R100 models represent the evolution of BMW's air-cooled boxer platform, starting from the /5 series and progressing through /6, /7, R45/65, R80/100GS, and R100R variants.
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Production
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Manufacturing Location:
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Berlin-Spandau, Germany
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Key Variants Covered:
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R80/7, R80G/S, R80ST, R80GS, R80R, R90/6, R90S, R100/7, R100S, R100CS, R100RS, R100RT, R100GS, R100R
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