The BMW R 80 GS, produced between 1991 and 1996, is a distinguished dual-sport motorcycle renowned for its robust engineering and impressive off-road capabilities, making it a formidable choice for adventure touring. This iconic model features a reliable air-cooled, four-stroke boxer twin-cylinder engine with a displacement of 797.5 cc, delivering approximately 50 horsepower and 42 lb-ft of torque. Its design philosophy emphasizes durability and long-range performance, complemented by a 5-speed manual gearbox and shaft drive. The R 80 GS is celebrated for its rugged construction, excellent range, and the enduring quality that has cemented its status in the adventure touring segment. This comprehensive service and repair manual provides in-depth technical guidance for the BMW R 80 GS models from 1991 to 1996, covering all essential aspects of maintenance, repair, and troubleshooting. With over 400 pages of detailed information, it encompasses engine overhauls, transmission servicing, chassis and electrical system repairs, brake system maintenance, and fuel system adjustments, including specific procedures for the Bing CV carburetors. The manual also details scheduled maintenance intervals, fluid specifications, and diagnostic procedures for common issues, offering invaluable support to owners and technicians aiming to preserve the performance and longevity of their R 80 GS. 🏷️ Basic Information Identification Make: BMW Model: R 80 GS Product Type: Service Repair Manual Codes Production Codes: BMW R 80 GS (1991-1996) 👋 Introduction Market Position Segment: Dual-sport motorcycle, known for its reliability and off-road capability. Competitive Analysis Competitors: Honda Africa Twin (XRV650/750), Yamaha Tenere (XT600Z), Kawasaki KLR650, Suzuki DR650. Key Features Design Philosophy: Robust, air-cooled boxer twin engine, shaft drive, durable construction, excellent range for adventure touring. Manual Value Proposition Completeness: Provides the most comprehensive information available for DIY mechanics and professional technicians working on this specific model range. 📋 Manual Details Coverage Areas Covered Model Years: 1991, 1992, 1993, 1994, 1995, 1996 Covered Engine Variants: R 80 GS (Airhead boxer engine) Page Count Estimated Page Count: 400+ Manual Type Type: Comprehensive Service and Repair Manual Language Language: English Format Format: Digital (likely PDF, potentially with printable pages) 📖 Manual Coverage Systems Covered Engine: Complete overhaul, disassembly, assembly, tuning, troubleshooting, lubrication, cooling system, fuel system (carburetors). Transmission: Gearbox (5-speed), clutch, drive shaft, final drive unit, maintenance, repair, troubleshooting. Chassis And Frame: Frame inspection, steering head bearings, swingarm, rear shock absorber replacement and adjustment, front fork overhaul and adjustment. Electrical System: Wiring diagrams, battery, charging system (alternator, regulator), ignition system (points, ignition coil, spark plugs), lighting, starter motor, troubleshooting. Brakes: Front and rear brake systems (disc brakes), hydraulic components, brake pad replacement, fluid flushing and bleeding, troubleshooting. Fuel System: Carburetor identification (e.g., Bing CV), disassembly, cleaning, adjustment, fuel tank, fuel lines, fuel pump (if applicable). Exhaust System: Exhaust pipe and muffler inspection, gasket replacement, tightening. Wheels And Tires: Wheel removal and installation, spoke tensioning, tire pressure recommendations, tire replacement. Bodywork And Fairings: Panel removal and installation, seat, fuel tank fairings, instrument cluster, headlight assembly. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements (oil, air), spark plug checks/replacement, valve clearance adjustment, carb synchronization, lubrication points. Repair: Engine rebuilds, transmission overhauls, brake caliper servicing, electrical component repair, suspension component replacement. Troubleshooting: Diagnostic procedures for common and uncommon issues, fault finding based on symptoms, electrical system diagnostics. Technical Data: Torque specifications for all fasteners, fluid capacities, component specifications, engine timings, electrical resistance values. Technical Depth Depth: In-depth mechanical and electrical repair, including full engine and transmission rebuilds, carburetor tuning, and advanced electrical troubleshooting. 📊 Manual Specifications File Format File Type: Likely PDF, designed for clear viewing and printing. Print Quality Readability: High-quality scans or originals ensuring clarity of text and diagrams. Binding Type Binding: N/A (digital format) Paper Type Paper Quality: N/A (digital format) ⚙️ Engine Specifications Primary Engine Type: Air-cooled, four-stroke, boxer twin-cylinder Displacement: 797.5 cc Bore X Stroke: 90.0 mm x 62.0 mm Compression Ratio: 8.5:1 Valve Train: Overhead camshaft (OHC), two valves per cylinder Performance Horsepower: Approximately 50 hp @ 6,500 rpm Torque: Approximately 57 Nm (42 lb-ft) @ 5,000 rpm Fuel System Carburetors: 2 x Bing 32mm Constant Velocity (CV) carburetors Fuel Type: Unleaded gasoline (premium recommended) Lubrication Oil Type: SAE 20W-50 or 10W-40 motorcycle-specific oil (refer to manual for exact specifications and change intervals). Oil Capacity: Approximately 3.0 liters (with filter change) Ignition Ignition Type: Contact breaker points and coil ignition 🔧 Transmission Standard Type: 5-speed manual gearbox Final Drive: Shaft drive Features Clutch: Single dry plate clutch Transmission Oil Type: Gearbox oil (refer to manual for specific viscosity and GL rating, often SAE 80W-90). Transmission Oil Capacity: Approximately 0.5 liters (refer to manual). 📐 Dimensions Exterior Length: Approx. 2,200 mm (Varies slightly by model year/configuration) Width: Approx. 920 mm (At handlebars) Height: Approx. 1,380 mm (Seat height approx. 860 mm) Weights Dry Weight: Approx. 190 kg Wet Weight: Approx. 210 kg Gross Vehicle Weight Rating: Approx. 370...