BMW R80 GS R100 R Motorcycle Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: BMW Model: R80 GS / R100 GS Model Series: R Series Airhead (Dual Sport) Chassis Codes: 247E (R80GS), 247E (R100GS) Vehicle Type: Dual Sport Motorcycle 👋 Introduction Market Position Segment: Iconic dual-sport motorcycles, renowned for their ruggedness and versatility for on-road and off-road touring. Competitive Analysis Competitors: Competed against bikes like Yamaha XT600, Honda Africa Twin (later models), Kawasaki KLR650. Key Features Engine Type: Air-cooled, horizontally opposed twin-cylinder ('boxer') Drivetrain Type: Shaft drive Suspension Design: Long-travel suspension, Monolever rear suspension (from 1987 onwards for R100GS, R80GS) or dual shocks (earlier GS models). Durability: Known for robust construction and reliability for long-distance travel and adventure riding. 📋 Manual Details Coverage Areas Engine: Yes Transmission: Yes Drivetrain: Yes Suspension: Yes Brakes: Yes Electrical System: Yes Fuel System: Yes Exhaust System: Yes Frame And Bodywork: Yes Wheels And Tires: Yes Tools And Special Equipment: Yes Troubleshooting: Yes Page Count Estimated Pages: Varies by specific edition, typically 300-500+ pages Manual Type Type: Workshop Repair Service Manual Language Language: English (likely, based on product description) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Internals: Cylinder head, valves, pistons, connecting rods, crankshaft, lubrication system, timing Fuel Delivery: Carburetor overhaul (Bing), fuel tank, fuel lines, fuel pump (if applicable) Ignition System: Ignition timing, spark plugs, coils, electronic ignition components Transmission Gearbox: Gear shifting mechanism, clutch operation, gearbox disassembly and assembly Final Drive: Driveshaft, universal joint, rear axle housing, final drive gears, bearings Front Suspension: Telescopic forks, fork seals, oil levels, springs, steering head bearings Rear Suspension: Monolever swingarm, shock absorber, linkage system (if applicable), pivot bearings Braking System: Hydraulic brake system, brake levers, master cylinders, calipers, brake discs, brake pads, bleeding procedures Electrical Components: Wiring diagrams, battery, starter motor, alternator, lights, horn, switches, fuses Chassis And Frame: Frame inspection, subframe, mounting points Procedures Included Routine Maintenance: Oil changes, filter replacement, spark plug checks, valve clearance adjustments, chain lubrication/adjustment (if applicable) Engine Rebuild: Top-end and bottom-end engine overhauls, component replacement Carburetor Tuning: Adjustment, cleaning, and synchronization of Bing carburetors Fork Rebuild: Fork seal replacement, oil level correction, spring replacement Shock ABSorber Service: Adjustment, replacement Brake Bleeding: Proper procedure for removing air from the hydraulic brake system Electrical Diagnostics: Troubleshooting common electrical faults using wiring diagrams Wheel Balancing: Tire mounting and wheel balancing procedures Bodywork Repair: Fairing, fuel tank, and fender removal/installation Technical Depth Depth: Comprehensive: Covers all aspects from basic maintenance to complete engine and component rebuilds. Diagnostic Capabilities: Includes common problems, symptoms, and diagnostic procedures. Torque Specifications: Detailed torque values for all critical fasteners. Illustrations: Clear, step-by-step illustrations and diagrams. 📊 Manual Specifications File Format Format: PDF Searchability: Typically text-searchable for easy information retrieval. Print Quality Quality: High-resolution for clear viewing of diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine R80Gs Engine Type: Air-cooled, four-stroke, horizontally opposed twin-cylinder (boxer) R80Gs Displacement: 797.5 cc (48.7 cu in) R80Gs Bore X Stroke: 84.8 mm x 70.6 mm R100Gs Engine Type: Air-cooled, four-stroke, horizontally opposed twin-cylinder (boxer) R100Gs Displacement: 980 cc (59.8 cu in) R100Gs Bore X Stroke: 94 mm x 70.6 mm Performance R80Gs Horsepower: Approx. 50 hp (37 kW) @ 6,500 rpm R80Gs Torque: Approx. 56 Nm (41 lb-ft) @ 5,000 rpm R100Gs Horsepower: Approx. 65 hp (48 kW) @ 7,000 rpm R100Gs Torque: Approx. 70 Nm (52 lb-ft) @ 5,500 rpm Fuel System Carburetion: Dual Bing Constant Velocity (CV) carburetors (e.g., 32mm for R80GS, 40mm for R100GS) Fuel Type: Unleaded gasoline Fuel Capacity: Approx. 24 liters (6.3 US gal), including reserve 🔧 Transmission Standard Type: 5-speed manual gearbox Features Clutch: Single dry plate clutch, hydraulically operated Final Drive: Shaft drive to rear wheel 📐 Dimensions Exterior Length: Varies by model year and specific configuration, typically around 2200 mm (86.6 in) Width: Approx. 800 mm (31.5 in) at handlebars Height: Varies by model and seat height, approx. 1300 mm (51.2 in) to top of screen Wheelbase: Approx. 1430 mm (56.3 in) Weights Dry Weight: R80GS: Approx. 190 kg (419 lbs); R100GS: Approx. 200 kg (441 lbs) Gross Vehicle Weight Rating: Approx. 390 kg (860 lbs) 🛡️ Safety Features Ratings Crash Test Data: N/A (Motorcycle specific crash testing standards differ significantly from automobiles) Active Features Braking System: Dual front disc brakes, single rear disc brake (dual piston calipers common on later models) Suspension Handling: Long-travel suspension designed for varied terrain, offering stability and control. Passive Features Lighting: Halogen headlight, taillight, turn signals. Frame Construction: Robust tubular steel frame for structural integrity. 💡 Technology Features Infotainment Features: Minimal by modern standards; primarily focused on mechanical operation. Features typically include analog gauges (speedometer, tachometer), odometer, trip meter, and indicator lights. Driver Assistance Features: None (N/A for this era of motorcycle). Connectivity Features: None (N/A for this era of motorcycle). 🔧 Maintenance...
Dual Bing Constant Velocity (CV) carburetors (e.g., 32mm for R80GS, 40mm for R100GS)
Fuel Type:
Unleaded gasoline
Fuel Capacity:
Approx. 24 liters (6.3 US gal), including reserve
🔧 Transmission
Standard
Type:
5-speed manual gearbox
Features
Clutch:
Single dry plate clutch, hydraulically operated
Final Drive:
Shaft drive to rear wheel
📐 Dimensions
Exterior
Length:
Varies by model year and specific configuration, typically around 2200 mm (86.6 in)
Width:
Approx. 800 mm (31.5 in) at handlebars
Height:
Varies by model and seat height, approx. 1300 mm (51.2 in) to top of screen
Wheelbase:
Approx. 1430 mm (56.3 in)
Weights
Dry Weight:
R80GS: Approx. 190 kg (419 lbs); R100GS: Approx. 200 kg (441 lbs)
Gross Vehicle Weight Rating:
Approx. 390 kg (860 lbs)
🛡️ Safety Features
Ratings
Crash Test Data:
N/A (Motorcycle specific crash testing standards differ significantly from automobiles)
Active Features
Braking System:
Dual front disc brakes, single rear disc brake (dual piston calipers common on later models)
Suspension Handling:
Long-travel suspension designed for varied terrain, offering stability and control.
Passive Features
Lighting:
Halogen headlight, taillight, turn signals.
Frame Construction:
Robust tubular steel frame for structural integrity.
💡 Technology Features
Infotainment
Features:
Minimal by modern standards; primarily focused on mechanical operation. Features typically include analog gauges (speedometer, tachometer), odometer, trip meter, and indicator lights.
Driver Assistance
Features:
None (N/A for this era of motorcycle).
Connectivity
Features:
None (N/A for this era of motorcycle).
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 - 10,000 km (3,000 - 6,000 miles) or annually, depending on usage. Refer to manual for exact intervals.
Valve Adjustment:
Every 10,000 - 20,000 km (6,000 - 12,000 miles), or as per manual recommendations.
Spark Plug Check:
Every 10,000 km (6,000 miles)
Brake Fluid Flush:
Every 2 years
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 20W-50 or 10W-40 recommended. Refer to manual for precise specifications.
Engine Oil Capacity:
Approx. 2.5 liters (2.6 US qt) with filter change
Transmission Oil Type:
SAE 90 Hypoid gear oil (GL-5)
Transmission Oil Capacity:
Approx. 0.9 liters (0.95 US qt)
Final Drive Oil Type:
SAE 90 Hypoid gear oil (GL-5)
Final Drive Oil Capacity:
Approx. 0.2 liters (0.21 US qt)
Fork Oil Type:
Brake fluid DOT 4 or specific motorcycle fork oil (e.g., 5W or 10W, depending on model year and preference)
Fork Oil Quantity:
Refer to manual; typically 200-230ml per fork leg
Known Issues
Engine Wear:
Oil leaks from the cylinder base gaskets or pushrod seals are common. Valve stem seals can degrade over time.
Electrical Issues:
Aging wiring harnesses can cause intermittent electrical problems. Alternator and starter motor brushes can wear out.
Transmission Reliability:
Generally robust, but clutch slave cylinder seals can fail. Gear selector indexing can sometimes be imprecise if not maintained.
Suspension Wear:
Fork seals are prone to leaks. Rear shock absorber may lose damping over time, especially on high-mileage bikes.
Fuel System Degradation:
Rubber fuel lines can perish. Carburetor internal components (diaphragms, jets) can become gummed up if the bike sits for extended periods.
Monolever Joint:
The universal joint in the Monolever system can wear, leading to clunking noises under acceleration/deceleration.
📚 Vehicle History
Brand Heritage
Legacy:
BMW Motorrad has a long history of producing durable, reliable motorcycles, particularly the boxer-twin R series, dating back to the mid-20th century.
Model Evolution
Gs Lineage:
The 'GS' (Gelände/Straße - Terrain/Street) designation originated with the R80G/S in 1980, establishing the adventure-touring segment. The R80GS and R100GS models were direct successors, expanding the engine displacement and capabilities.
R100Gs Introduction:
Introduced in 1987 as an evolution of the R80G/S and R80GS, featuring the larger 1000cc engine and the new Monolever single-sided swingarm/driveshaft system.
R80Gs Introduction:
Introduced in 1987 as a slightly smaller displacement version of the GS concept, often sharing many components with the R100GS.
Widely regarded as classic adventure touring motorcycles, highly sought after by enthusiasts for their durability and classic appeal. Often featured in 'best adventure bikes of all time' lists.
Ratings
Owner Satisfaction:
High owner satisfaction due to reliability and the unique riding experience. However, maintenance requires more hands-on knowledge compared to contemporary bikes.
Certifications
Emission Standards:
Compliant with emission standards of their respective production years, which were less stringent than modern requirements.
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