BMW R80 R90 R100 1978-1996 Motorcycle Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: BMW Model: R Series (R80, R90, R100) Manufacturer Code: BMW Motorrad Generation Covered Production Years: 1978-1996 Codes Chassis Codes Covered: R80/7, R80GS, R80RT, R90/6, R90S, R100/7, R100S, R100RT, R100RS, R100GS, R100R, R100CS, R100T 👋 Introduction Market Position Segment: Premium/Classic Motorcycle Segment Target Audience: Owners, enthusiasts, independent repair shops specializing in vintage BMW motorcycles Competitive Analysis Competitors Manuals: Haynes, Clymer, factory service manuals (often rare and expensive) Advantage: Comprehensive coverage across multiple models and years in a single, accessible format Key Features Illustration Quality: Illustrated with clear, step-by-step instructions Completeness: Offers complete service, repair, and diagnostic information Accessibility: Digital format allows for instant download and easy searchability 📋 Manual Details Coverage Areas Engine Overhaul: Complete Transmission Repair: Complete Electrical System Diagnostics: Comprehensive Chassis And Suspension: Complete Bodywork And Trim: Detailed Troubleshooting Guides: Extensive Page Count Estimated Page Count: 400-600 (Varies by specific model and edition) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: BMW Boxer twin-cylinder, air-cooled (2-valve and 4-valve variants where applicable) Fuel System: Carburetor systems (Bing), fuel injection systems (Motronic where applicable) Ignition System: Breaker-point ignition, electronic ignition systems Transmission: 5-speed and 4-speed manual gearboxes, clutch systems (dry single-plate and dual-plate) Drivetrain: Shaft drive, final drive units Brakes: Drum brakes, disc brakes (single and dual front discs), braking system hydraulics Suspension: Telescopic forks,モノショック (Monolever, Paralever) rear suspension systems Electrical System: Wiring diagrams, lighting, starting system, charging system (alternator, regulator), instrumentation Frame And Bodywork: Frame inspection and repair, body panels, fuel tank, seat, fairings (where applicable) Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, brake adjustments, chain/shaft lubrication Engine Rebuild: Piston and cylinder removal/installation, valve adjustments, crankshaft and connecting rod service, seal replacement Transmission Rebuild: Gearbox disassembly and reassembly, bearing replacement, shift mechanism repair Carburetor And Fuel Injection Tuning: Adjustment, cleaning, rebuilding, synchronization Electrical Diagnostics: Troubleshooting starting and charging issues, wiring harness repair, component testing Suspension Service: Fork seal replacement, shock absorber service, linkage maintenance Brake System Service: Bleeding, pad/shoe replacement, caliper/master cylinder rebuilding Wheel And Tire Service: Tire replacement, wheel balancing, spoke tensioning (where applicable) Troubleshooting Charts: Common symptoms and their causes, diagnostic steps Technical Depth Level Of Detail: In-depth, suitable for professional mechanics and experienced DIY enthusiasts Diagnostic Information: Includes specific diagnostic procedures, torque specifications, and troubleshooting flowcharts Rebuild Procedures: Detailed steps for complete engine, transmission, and component overhauls Wiring Diagrams: Clear, comprehensive wiring schematics for all electrical systems Special Tools: Lists and descriptions of specialized tools required for certain procedures 📊 Manual Specifications File Format Format Type: Portable Document Format (PDF) Searchability: Searchable text for quick information retrieval Resolution: High resolution, clear images and diagrams Print Quality Printability: Printable for offline use, individual chapters or full manual Binding Type Binding Digital: N/A (Digital Download) Paper Type Paper Digital: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Configuration: Air-cooled, four-stroke, boxer twin-cylinder Engine Displacement R80: 797.5 cc (for R80 models) Engine Displacement R90: 897.1 cc (for R90/6 and R90S) Engine Displacement R100: 979.7 cc (for R100 models) Valve Train: Overhead valves, pushrod actuated (2-valve typically), some R100 variants featured 4-valve heads Performance Horsepower R80: Approx. 50-60 hp (varies by specific R80 model and tuning) Horsepower R90: Approx. 60-67 hp (R90S typically higher) Horsepower R100: Approx. 65-70 hp (varies by specific R100 model and tuning) Torque: Significant low-end torque characteristic of BMW boxer engines Fuel System Carburetors R80 R90: Dual Bing 32mm or 40mm constant-velocity carburetors (e.g., 64/32/17-19) Carburetors R100: Dual Bing 32mm or 40mm CV carburetors (e.g., 64/40/301) Fuel Injection Systems: Bosch Motronic (on later R100 models) Fuel Type: Unleaded gasoline, Octane rating 90-95 RON (Research Octane Number) 🔧 Transmission Standard Type R80 R90: 5-speed constant mesh manual gearbox Type R100: 5-speed constant mesh manual gearbox (some earlier R100 models may have had 4-speed) Optional Gearbox Variants: Some variations in gear ratios across different models and years Features Clutch Type: Dry single-plate diaphragm spring clutch (most models); some high-performance variants (like R90S) may have had dual-plate options. Final Drive: Enclosed shaft drive with hypoid bevel gear final drive 📐 Dimensions Exterior Wheelbase: Approx. 1450-1500 mm (varies by model) Seat Height: Approx. 780-820 mm (varies by model) Weights Dry Weight: Approx. 200-230 kg (varies significantly by model and equipment) Gross Vehicle Weight Rating: Approx. 400-430 kg (varies by model) 🛡️ Safety Features Ratings Crash Test Data: Not applicable in the same way as modern cars; safety focused on rider control and braking performance. Active Features Braking System: Dual disc front brakes (on many later models), single disc rear or drum brakes, providing effective stopping power. Suspension Stability: Well-engineered suspension systems (Monolever, Paralever) contribute to stability and handling. Passive Features Frame Integrity: Robust steel tube frame provides a strong and stable chassis. Lighting: Adequate headlight, taillight, and indicator lighting for...
Common symptoms and their causes, diagnostic steps
Technical Depth
Level Of Detail:
In-depth, suitable for professional mechanics and experienced DIY enthusiasts
Diagnostic Information:
Includes specific diagnostic procedures, torque specifications, and troubleshooting flowcharts
Rebuild Procedures:
Detailed steps for complete engine, transmission, and component overhauls
Wiring Diagrams:
Clear, comprehensive wiring schematics for all electrical systems
Special Tools:
Lists and descriptions of specialized tools required for certain procedures
📊 Manual Specifications
File Format
Format Type:
Portable Document Format (PDF)
Searchability:
Searchable text for quick information retrieval
Resolution:
High resolution, clear images and diagrams
Print Quality
Printability:
Printable for offline use, individual chapters or full manual
Binding Type
Binding Digital:
N/A (Digital Download)
Paper Type
Paper Digital:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Configuration:
Air-cooled, four-stroke, boxer twin-cylinder
Engine Displacement R80:
797.5 cc (for R80 models)
Engine Displacement R90:
897.1 cc (for R90/6 and R90S)
Engine Displacement R100:
979.7 cc (for R100 models)
Valve Train:
Overhead valves, pushrod actuated (2-valve typically), some R100 variants featured 4-valve heads
Performance
Horsepower R80:
Approx. 50-60 hp (varies by specific R80 model and tuning)
Horsepower R90:
Approx. 60-67 hp (R90S typically higher)
Horsepower R100:
Approx. 65-70 hp (varies by specific R100 model and tuning)
Torque:
Significant low-end torque characteristic of BMW boxer engines
Fuel System
Carburetors R80 R90:
Dual Bing 32mm or 40mm constant-velocity carburetors (e.g., 64/32/17-19)
Carburetors R100:
Dual Bing 32mm or 40mm CV carburetors (e.g., 64/40/301)
Fuel Injection Systems:
Bosch Motronic (on later R100 models)
Fuel Type:
Unleaded gasoline, Octane rating 90-95 RON (Research Octane Number)
🔧 Transmission
Standard
Type R80 R90:
5-speed constant mesh manual gearbox
Type R100:
5-speed constant mesh manual gearbox (some earlier R100 models may have had 4-speed)
Optional
Gearbox Variants:
Some variations in gear ratios across different models and years
Features
Clutch Type:
Dry single-plate diaphragm spring clutch (most models); some high-performance variants (like R90S) may have had dual-plate options.
Final Drive:
Enclosed shaft drive with hypoid bevel gear final drive
📐 Dimensions
Exterior
Wheelbase:
Approx. 1450-1500 mm (varies by model)
Seat Height:
Approx. 780-820 mm (varies by model)
Weights
Dry Weight:
Approx. 200-230 kg (varies significantly by model and equipment)
Gross Vehicle Weight Rating:
Approx. 400-430 kg (varies by model)
🛡️ Safety Features
Ratings
Crash Test Data:
Not applicable in the same way as modern cars; safety focused on rider control and braking performance.
Active Features
Braking System:
Dual disc front brakes (on many later models), single disc rear or drum brakes, providing effective stopping power.
Suspension Stability:
Well-engineered suspension systems (Monolever, Paralever) contribute to stability and handling.
Passive Features
Frame Integrity:
Robust steel tube frame provides a strong and stable chassis.
Lighting:
Adequate headlight, taillight, and indicator lighting for visibility.
💡 Technology Features
Infotainment
Availability:
None (These are classic motorcycles focused on mechanical function, not modern electronics)
Driver Assistance
Features:
None (Focus on mechanical systems and rider input)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 10,000 km (3,000 - 6,000 miles) or annually, depending on usage and specific model year.
Valve Adjustment Interval:
Every 10,000 km (6,000 miles) is a common recommendation for these engines.
Spark Plug Replacement:
Every 10,000 - 20,000 km (6,000 - 12,000 miles)
Brake Fluid Flush:
Every 2 years (regardless of mileage)
Fluid Specifications
Engine Oil Type:
SAE 20W-50 or SAE 15W-40 mineral or semi-synthetic motorcycle oil (API SG or higher). Check manual for specific grade.
Engine Oil Capacity:
Approximately 2.5 - 3.0 liters (2.6 - 3.2 US quarts) with filter change.
Gearbox Oil Type:
SAE 80W/90 API GL-4 Hypoid gear oil.
Final Drive Oil Type:
SAE 80W/90 API GL-5 Hypoid gear oil.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Known Issues
Oil Leaks:
Common at pushrod tube seals, base gasket, and final drive output seals. Manual details replacement procedures.
Pushrod Tube Seals:
Degradation leads to oil seepage. Detailed replacement instructions are provided.
Gearbox Shifting:
Can become notchy or difficult with wear. Manual covers adjustment and internal inspection.
Charging System:
Rotor and regulator failures can occur. Manual details testing and replacement.
Electrical Connections:
Corrosion or loose connections can lead to intermittent issues. Manual provides wiring diagrams for troubleshooting.
📚 Vehicle History
Brand Heritage
Bmw Motorrad Legacy:
BMW Motorrad has a long history of producing reliable, durable, and technologically advanced motorcycles, particularly known for its boxer engines and shaft drive.
Model Evolution
R Series Development:
The R80, R90, and R100 models represent a significant evolution of BMW's boxer-twin platform, moving from the earlier /5, /6, and /7 series to more refined and powerful iterations.
Key Innovations:
Introduction of Monolever and Paralever rear suspension systems in later models improved handling and reduced maintenance. Advancements in braking systems, including dual front discs. Evolution of fuel injection systems.
Production
Manufacturing Location:
Berlin-Spandau, Germany
Production Period:
The R80 series ran from 1977-1995, R90 from 1973-1976, and R100 from 1976-1996. The manual covers this entire span.
🏆 Awards & Recognition
Recognitions
General Reputation:
Highly regarded for their durability, engineering, and classic styling. Often considered 'modern classics' or 'endurance' bikes.
Ratings
Reliability:
Generally excellent reliability when properly maintained, earning a strong reputation among riders.
Certifications
Manual Quality:
A comprehensive and essential resource for owners and technicians.