BMW R80 GS R100 R 1978-1996 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: BMW Model: R80 GS / R100 R Model Variants: R80GS, R100GS, R100R Codes Vin Code: N/A (Specific VIN decoders required for individual models) Generation Generation: Airhead platform (covering the significant evolution of these models) 👋 Introduction Market Position Target Audience: Owners with basic mechanical skills, independent repair shops, and professional BMW technicians. Competitive Analysis Value Proposition: Provides dealership-level repair and maintenance information, enabling significant cost savings on common services and repairs. Key Features Content Type: Vehicle-specific, not generic information; includes step-by-step instructions, diagrams, and wiring schematics. Manufacturer Origin: Written by manufacturers, mirroring the content used by authorized dealer service departments. 📋 Manual Details Coverage Areas Years Covered: 1978-1996 Specific Years: 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996 Page Count Estimated Page Count: Extensive (typical workshop manuals for this era are 500+ pages, exact count not provided but implied to be comprehensive) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Internal combustion engine (air-cooled flat-twin, boxer), including disassembly, assembly, inspection, and repair of all components. Fuel System: Carburetor systems (e.g., Bing), fuel pumps, fuel tanks, fuel lines, and related components. Cooling System: Air cooling system management, including oil cooling where applicable (e.g., R100 models). Transmission: Gearbox operation, maintenance, repair, clutch system, and internal components. Drive Train: Final drive, driveshaft, universal joints, rear drive unit, and associated components. Electrical System: Ignition system (points/electronic), charging system (alternator/generator), lighting, starter motor, battery, and wiring harnesses. Braking System: Hydraulic disc brakes (front and rear), brake calipers, master cylinders, brake lines, and related maintenance. Suspension: Front forks (telescopic), rear swingarm, shock absorbers (e.g., Koni, Bilstein depending on model/year), and fork seals. Steering System: Handlebar assembly, steering head bearings, and related components. Bodywork: Frame, fuel tank, fenders, seat, fairings (if equipped), and other body components. Wheels And Tires: Wheel bearing maintenance, spoke adjustment, and tire specifications. Exhaust System: Exhaust headers, mufflers, and mounting components. Procedures Included Maintenance: Routine maintenance, periodic checks, oil changes, filter replacements, spark plug servicing, lubrication points. Repair: Step-by-step repair instructions for all major systems, including engine rebuilds, transmission overhauls, and electrical troubleshooting. Troubleshooting: Advanced troubleshooting guides for diagnosing and resolving common and uncommon problems. Adjustments: Carburetor synchronization, valve clearance adjustments, ignition timing, clutch and brake lever adjustments. Disassembly Assembly: Detailed instructions for removing and reinstalling major components and sub-assemblies. Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and gearbox rebuilds. Includes diagnostic procedures and specifications for professional technicians. Illustrations Diagrams And Schematics: Detailed diagrams, illustrations, and wiring schematics for clear visual guidance. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Printable pages, allowing users to print specific sections as needed for workshop use. Binding Type Binding: N/A (Digital download format) Paper Type Paper Quality: N/A (Digital download format) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, four-stroke, horizontally opposed twin-cylinder boxer engine. Displacements: Typically 797cc (R80GS) and 980cc (R100GS/R100R). Bore X Stroke: R80GS: 80.0 mm x 78.0 mm; R100GS/R100R: 94.0 mm x 70.7 mm (specifications vary slightly by sub-model/year) Performance Horsepower Range: R80GS: approx. 50 hp; R100GS/R100R: approx. 65-70 hp (dependent on model year and tuning) Torque Range: R80GS: approx. 53 Nm; R100GS/R100R: approx. 70-75 Nm (dependent on model year and tuning) Fuel System Carburetors: Typically dual Bing carburetors (e.g., 32mm or 40mm, depending on model). Ignition System Ignition Type: Mechanical points ignition transitioning to electronic ignition systems over the covered years. 🔧 Transmission Standard Type: 5-speed constant mesh gearbox. Optional Optional Features: N/A (Standard configuration for these models) Features Clutch Type: Single dry plate clutch, operated hydraulically. Fluid Type Gearbox Oil: Typically SAE 90 gear oil (refer to manual for precise BMW specifications and viscosity grades). 📐 Dimensions Exterior Wheelbase: Variable by model, but generally around 1400-1450 mm. Weights Dry Weight: R80GS: approx. 185 kg; R100GS: approx. 195-205 kg; R100R: approx. 185 kg (dry, without fluids). Fuel Capacity: Typically 19-20 liters (4.2-4.4 US gallons), including reserve. 🛡️ Safety Features Ratings Crash Test Results: N/A (Motorcycles from this era were not subjected to standardized crash testing like modern automobiles). Active Features Braking System: Effective hydraulic disc brakes on both front and rear wheels for significant stopping power. Passive Features Chassis Design: Robust frame construction providing stability and rider confidence. 💡 Technology Features Infotainment Features: N/A (Motorcycles of this era did not feature modern infotainment systems). Driver Assistance Features: N/A (Focus is on core mechanical and electrical systems). Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000 - 10,000 km (3,000 - 6,000 miles) or annually, depending on usage. Refer to manual for exact intervals. Valve Adjustment Interval: Generally every 10,000 km (6,000 miles). Fluid Specifications Engine Oil: Typically SAE 20W-50 or SAE 15W-50 motorcycle-specific oil....
Step-by-step repair instructions for all major systems, including engine rebuilds, transmission overhauls, and electrical troubleshooting.
Troubleshooting:
Advanced troubleshooting guides for diagnosing and resolving common and uncommon problems.
Adjustments:
Carburetor synchronization, valve clearance adjustments, ignition timing, clutch and brake lever adjustments.
Disassembly Assembly:
Detailed instructions for removing and reinstalling major components and sub-assemblies.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete engine and gearbox rebuilds. Includes diagnostic procedures and specifications for professional technicians.
Illustrations
Diagrams And Schematics:
Detailed diagrams, illustrations, and wiring schematics for clear visual guidance.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Printable pages, allowing users to print specific sections as needed for workshop use.
R80GS: 80.0 mm x 78.0 mm; R100GS/R100R: 94.0 mm x 70.7 mm (specifications vary slightly by sub-model/year)
Performance
Horsepower Range:
R80GS: approx. 50 hp; R100GS/R100R: approx. 65-70 hp (dependent on model year and tuning)
Torque Range:
R80GS: approx. 53 Nm; R100GS/R100R: approx. 70-75 Nm (dependent on model year and tuning)
Fuel System
Carburetors:
Typically dual Bing carburetors (e.g., 32mm or 40mm, depending on model).
Ignition System
Ignition Type:
Mechanical points ignition transitioning to electronic ignition systems over the covered years.
🔧 Transmission
Standard
Type:
5-speed constant mesh gearbox.
Optional
Optional Features:
N/A (Standard configuration for these models)
Features
Clutch Type:
Single dry plate clutch, operated hydraulically.
Fluid Type
Gearbox Oil:
Typically SAE 90 gear oil (refer to manual for precise BMW specifications and viscosity grades).
📐 Dimensions
Exterior
Wheelbase:
Variable by model, but generally around 1400-1450 mm.
Weights
Dry Weight:
R80GS: approx. 185 kg; R100GS: approx. 195-205 kg; R100R: approx. 185 kg (dry, without fluids).
Fuel Capacity:
Typically 19-20 liters (4.2-4.4 US gallons), including reserve.
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (Motorcycles from this era were not subjected to standardized crash testing like modern automobiles).
Active Features
Braking System:
Effective hydraulic disc brakes on both front and rear wheels for significant stopping power.
Passive Features
Chassis Design:
Robust frame construction providing stability and rider confidence.
💡 Technology Features
Infotainment
Features:
N/A (Motorcycles of this era did not feature modern infotainment systems).
Driver Assistance
Features:
N/A (Focus is on core mechanical and electrical systems).
Connectivity
Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 10,000 km (3,000 - 6,000 miles) or annually, depending on usage. Refer to manual for exact intervals.
Valve Adjustment Interval:
Generally every 10,000 km (6,000 miles).
Fluid Specifications
Engine Oil:
Typically SAE 20W-50 or SAE 15W-50 motorcycle-specific oil. Refer to manual for precise BMW specifications (e.g., BMW High Performance Oil).
Brake Fluid:
DOT 4 hydraulic brake fluid.
Fork Oil:
Specific weight fork oil (e.g., SAE 7.5W or 10W), quantity specified per fork leg in the manual.
Known Issues
Common Wear Items:
Clutch wear, final drive spline lubrication, output shaft seal leaks, steering head bearing adjustment, carburetor synchronization.
Gs Specific Considerations:
Paralever rear drive unit maintenance (if applicable to specific models), spoke tension for off-road use.
📚 Vehicle History
Brand Heritage
Bmw Motorrad Legacy:
BMW Motorrad has a long and storied history, renowned for engineering excellence, durability, and reliability, particularly in the boxer-twin platform.
Model Evolution
Airhead Development:
The R80GS and R100GS/R are part of the iconic 'Airhead' series, representing a significant evolution of BMW's boxer-twin motorcycles, blending touring comfort with off-road capability (GS models).
Production
Production Period:
The R80GS was introduced in 1980, and the R100GS and R100R were introduced in 1987. Production of these 'airhead' models continued through 1996.
Manufacturing Locations:
Germany (Berlin-Spandau plant).
🏆 Awards & Recognition
Recognitions
Model Reputation:
The 'Airhead' BMWs, including the R80GS and R100GS, are widely regarded as durable, reliable, and capable motorcycles, particularly the GS models for their adventure touring prowess.
Ratings
Industry Standing:
Highly respected within the motorcycle community for their build quality and longevity.