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BMW R850 R850GS 1994-2001 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: R850R Model Variant: R850GS Model Years Covered: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001 Codes Chassis Code: R259 👋 Introduction Market Position Market Segment: Adventure Touring / Sport Touring Motorcycle Competitive Analysis Competitors: Honda VFR750/800, Yamaha Diversion/XJ series, Kawasaki GTR series, Moto Guzzi California/Tonti frame bikes. Key Features Unique Selling Points: BMW's signature boxer twin engine, shaft drive, robust build quality, comfortable ergonomics for long-distance riding, capable on varied surfaces (GS variant). 📋 Manual Details Coverage Areas Manual Type: Workshop Repair Service Manual Language: English Format: PDF Download Coverage Scope: Service, Maintenance, Troubleshooting, Repair 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, tuning, lubrication system, cooling system (air-cooled), fuel injection system (Bosch Motronic), ignition system, exhaust system. Transmission: Gearbox service, clutch operation, final drive (single-sided swingarm with driveshaft), gearbox oil change and inspection. Chassis Suspension: Front suspension (forks), rear suspension (Monolever system with adjustable shock absorber), wheel bearing maintenance, steering head bearing service. Brakes: Front and rear brake system service, ABS (Anti-lock Braking System) troubleshooting and bleeding, brake pad replacement, brake fluid specifications and change intervals. Electrical System: Battery maintenance and testing, charging system (alternator), starter motor, lighting system (headlights, taillights, indicators), instrument cluster, wiring diagrams, fuse identification and replacement. Bodywork Frame: Fairing removal and installation, seat removal, fuel tank servicing, body panel repair and alignment, frame inspection. Procedures Included Maintenance: Regular service checks, oil and filter changes, spark plug replacement, air filter cleaning/replacement, brake inspection, clutch adjustment, valve clearance checks and adjustment. Troubleshooting: Diagnosis of common running issues, electrical faults, starting problems, braking system concerns, suspension irregularities. Repair: Detailed step-by-step instructions for component replacement, rebuilding of sub-assemblies, and general repairs. Diagnostics: Fault code interpretation (if applicable via diagnostic tools), component testing procedures. Torque Specifications: All critical fastener torque values provided for engine, chassis, and suspension components. Special Tools: Identifies required special tools for specific procedures (e.g., flywheel holder, clutch alignment tool). Technical Depth Depth: Comprehensive, covering routine maintenance to complete engine and gearbox rebuilds, advanced electrical diagnostics. Wiring Diagrams: Detailed, system-specific wiring schematics included for troubleshooting. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Yes (typically) Printable: Yes Print Quality Quality: High-resolution, professional scan (assumed for a quality PDF download). Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, air-cooled, boxer-twin (Flat-twin) Displacement: 848 cc (approximately) Bore X Stroke: 90.0 mm x 66.0 mm (approximate) Compression Ratio: 10.0:1 (typical) Valve Train: SOHC (Single Overhead Camshaft) per cylinder, 2 valves per cylinder. Performance Horsepower: Approx. 70-80 hp @ 7000-7500 rpm (depending on specific tuning and regulations) Torque: Approx. 70-75 Nm @ 5000-6000 rpm (depending on specific tuning and regulations) Fuel System Fuel Delivery: Bosch Motronic Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (91-98 RON / 87-93 AKI recommended) Fuel Tank Capacity: Approx. 23 liters (5.0 Imp gal / 6.1 US gal) 🔧 Transmission Standard Transmission Type: 5-speed manual Clutch: Single dry plate clutch, hydraulically actuated Optional Optional Transmission: N/A (Standard 5-speed manual) Features Final Drive: Shaft drive to rear wheel via single-sided swingarm (Monolever system) Gearbox Oil Type: GL-5 SAE 75W-90 (or BMW equivalent) 📐 Dimensions Exterior Length: Approx. 2170 mm (R850GS variant) Width: Approx. 910 mm (R850GS variant, including mirrors) Height: Approx. 1300 mm (R850GS variant, to top of windscreen) Wheelbase: Approx. 1430 mm Weights Dry Weight: Approx. 215 kg Curb Weight: Approx. 230 kg (fully fueled) Gross Vehicle Weight Rating: Approx. 440 kg 🛡️ Safety Features Ratings ABS Availability: Optional ABS (BMW Motorrad ABS II) Active Features Braking System: Dual 305mm discs with dual piston calipers (front), Single 276mm disc with dual piston caliper (rear). Lighting: Halogen headlight, LED taillight (typical). Passive Features Frame Construction: Steel tube frame 💡 Technology Features Infotainment Instrumentation: Analog speedometer and tachometer, LCD display for odometer, trip meter, clock, fuel level, and warning lights. Driver Assistance ABS: Optional ABS system with independent front and rear control, or linked system depending on exact build. Connectivity Diagnostic Port: BMW proprietary diagnostic connector for advanced diagnostics (requires specific BMW tools or compatible aftermarket units). 🔧 Maintenance Service Intervals Oil Change Interval: Every 10,000 km or annually (whichever comes first) Valve Check Interval: Every 20,000 km Spark Plug Replacement: Every 20,000 km Fluid Specifications Engine Oil Type: API SG/SH or higher, SAE 15W-40 or 20W-50 (check manual for precise recommendation based on climate) Engine Oil Capacity: Approx. 2.5 liters (with filter change) Brake Fluid Type: DOT 4 Coolant Type: N/A (Air-cooled engine) Known Issues Common Wear Items: Clutch friction plates, paralever ball joint, steering head bearings, rear shock absorber damping. Electrical Quirks: Occasional issues with alternator output or voltage regulator; check wiring loom integrity, especially at the starter solenoid. 📚 Vehicle History Brand Heritage Brand Focus: BMW Motorrad has a long history of producing...
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BMW R850 R850GS 1994-2001 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
R850R
Model Variant:
R850GS
Model Years Covered:
1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001
Codes
Chassis Code:
R259
👋 Introduction
Market Position
Market Segment:
Adventure Touring / Sport Touring Motorcycle
Competitive Analysis
Competitors:
Honda VFR750/800, Yamaha Diversion/XJ series, Kawasaki GTR series, Moto Guzzi California/Tonti frame bikes.
Key Features
Unique Selling Points:
BMW's signature boxer twin engine, shaft drive, robust build quality, comfortable ergonomics for long-distance riding, capable on varied surfaces (GS variant).
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Repair Service Manual
Language:
English
Format:
PDF Download
Coverage Scope:
Service, Maintenance, Troubleshooting, Repair
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, tuning, lubrication system, cooling system (air-cooled), fuel injection system (Bosch Motronic), ignition system, exhaust system.
Transmission:
Gearbox service, clutch operation, final drive (single-sided swingarm with driveshaft), gearbox oil change and inspection.
Chassis Suspension:
Front suspension (forks), rear suspension (Monolever system with adjustable shock absorber), wheel bearing maintenance, steering head bearing service.
Brakes:
Front and rear brake system service, ABS (Anti-lock Braking System) troubleshooting and bleeding, brake pad replacement, brake fluid specifications and change intervals.
Electrical System:
Battery maintenance and testing, charging system (alternator), starter motor, lighting system (headlights, taillights, indicators), instrument cluster, wiring diagrams, fuse identification and replacement.
Bodywork Frame:
Fairing removal and installation, seat removal, fuel tank servicing, body panel repair and alignment, frame inspection.
Procedures Included
Maintenance:
Regular service checks, oil and filter changes, spark plug replacement, air filter cleaning/replacement, brake inspection, clutch adjustment, valve clearance checks and adjustment.
Troubleshooting:
Diagnosis of common running issues, electrical faults, starting problems, braking system concerns, suspension irregularities.
Repair:
Detailed step-by-step instructions for component replacement, rebuilding of sub-assemblies, and general repairs.
Diagnostics:
Fault code interpretation (if applicable via diagnostic tools), component testing procedures.
Torque Specifications:
All critical fastener torque values provided for engine, chassis, and suspension components.
Special Tools:
Identifies required special tools for specific procedures (e.g., flywheel holder, clutch alignment tool).
Technical Depth
Depth:
Comprehensive, covering routine maintenance to complete engine and gearbox rebuilds, advanced electrical diagnostics.
Wiring Diagrams:
Detailed, system-specific wiring schematics included for troubleshooting.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes (typically)
Printable:
Yes
Print Quality
Quality:
High-resolution, professional scan (assumed for a quality PDF download).
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, air-cooled, boxer-twin (Flat-twin)
Displacement:
848 cc (approximately)
Bore X Stroke:
90.0 mm x 66.0 mm (approximate)
Compression Ratio:
10.0:1 (typical)
Valve Train:
SOHC (Single Overhead Camshaft) per cylinder, 2 valves per cylinder.
Performance
Horsepower:
Approx. 70-80 hp @ 7000-7500 rpm (depending on specific tuning and regulations)
Torque:
Approx. 70-75 Nm @ 5000-6000 rpm (depending on specific tuning and regulations)
Fuel System
Fuel Delivery:
Bosch Motronic Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (91-98 RON / 87-93 AKI recommended)
Fuel Tank Capacity:
Approx. 23 liters (5.0 Imp gal / 6.1 US gal)
🔧 Transmission
Standard
Transmission Type:
5-speed manual
Clutch:
Single dry plate clutch, hydraulically actuated
Optional
Optional Transmission:
N/A (Standard 5-speed manual)
Features
Final Drive:
Shaft drive to rear wheel via single-sided swingarm (Monolever system)
Gearbox Oil Type:
GL-5 SAE 75W-90 (or BMW equivalent)
📐 Dimensions
Exterior
Length:
Approx. 2170 mm (R850GS variant)
Width:
Approx. 910 mm (R850GS variant, including mirrors)
Height:
Approx. 1300 mm (R850GS variant, to top of windscreen)
Wheelbase:
Approx. 1430 mm
Weights
Dry Weight:
Approx. 215 kg
Curb Weight:
Approx. 230 kg (fully fueled)
Gross Vehicle Weight Rating:
Approx. 440 kg
🛡️ Safety Features
Ratings
ABS Availability:
Optional ABS (BMW Motorrad ABS II)
Active Features
Braking System:
Dual 305mm discs with dual piston calipers (front), Single 276mm disc with dual piston caliper (rear).
Lighting:
Halogen headlight, LED taillight (typical).
Passive Features
Frame Construction:
Steel tube frame
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer and tachometer, LCD display for odometer, trip meter, clock, fuel level, and warning lights.
Driver Assistance
ABS:
Optional ABS system with independent front and rear control, or linked system depending on exact build.
Connectivity
Diagnostic Port:
BMW proprietary diagnostic connector for advanced diagnostics (requires specific BMW tools or compatible aftermarket units).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km or annually (whichever comes first)
Valve Check Interval:
Every 20,000 km
Spark Plug Replacement:
Every 20,000 km
Fluid Specifications
Engine Oil Type:
API SG/SH or higher, SAE 15W-40 or 20W-50 (check manual for precise recommendation based on climate)
Engine Oil Capacity:
Approx. 2.5 liters (with filter change)
Brake Fluid Type:
DOT 4
Coolant Type:
N/A (Air-cooled engine)
Known Issues
Common Wear Items:
Clutch friction plates, paralever ball joint, steering head bearings, rear shock absorber damping.
Electrical Quirks:
Occasional issues with alternator output or voltage regulator; check wiring loom integrity, especially at the starter solenoid.
📚 Vehicle History
Brand Heritage
Brand Focus:
BMW Motorrad has a long history of producing reliable, technologically advanced motorcycles, often with a focus on touring and adventure.
Model Evolution
Predecessor:
Evolution from the R850R (Roadster) platform, the GS variant adds longer travel suspension and spoke wheels for light off-road capability.
Successor:
Models like the R1150GS and subsequent R1200GS series took over the adventure touring segment.
Production
Manufacturing Location:
Berlin, Germany (BMW Motorrad plant)
Production Period:
R850GS model production started in 1994 and continued through 2001 for this generation.
🏆 Awards & Recognition
Recognitions
Awards Received:
While specific awards for the R850GS are not widely publicized, the R-series platform itself has consistently received praise for reliability, engineering, and touring capability.
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