1994–2005 BMW R 1100 RS/RT, R 850/1100 GS, and R 850/1100 R OEM Service Manual (P/N UX-VS-2, 02/00)

• Official BMW Motorrad After Sales repair manual for the R 1100 RT, R 1100 RS, R 850 GS, R 1100 GS, R 850 R, and R 1100 R. This 464-page A4 PDF was produced in Germany in 02/00 and bears the BMW imprint UX-VS-2.
• Covers engine removal, complete teardown and reassembly, cylinder-head repair, valve and guide work, piston/cylinder inspection, crankshaft and connecting-rod measurement, oil-pump service, timing-chain installation, and ignition timing.
• Details single-plate dry-clutch and five-speed gearbox repair, including shaft, bearing, seal, selector, shimming, and Clean Bearing procedures, with separate data for 1993 and M94 gearboxes.
• Documents rear-wheel-drive and Paralever overhaul: bevel-pinion and crown-wheel work, backlash and tooth-contact checks, housing-cover shimming, driveshaft and universal-joint inspection, swingarm bearings, and suspension-strut removal.
• Handles Telelever, wheel, and brake work, including fork and leading-link service, ball-joint checks, cast and spoked wheels, caliper and master-cylinder repair, hydraulic bleeding, ABS unit and relay replacement, brake-line service, and sensor adjustment.
• Includes Motronic MA 2.2 fuel-system and engine-electrical procedures for injectors, fuel pump and pressure regulator, throttle synchronization, ignition coil, alternator, starter, Hall-effect trigger, relays, fuses, and model-specific harness routing.
• Supplies model-specific torque data, capacities, pressure tests, wear limits, clearances, bearing fits, adjustment values, and electrical test specifications, with BMW special-tool callouts throughout.

This factory repair manual follows the workshop sequence of removal, disassembly, repair, assembly, and installation across BMW Construction Groups 00 through 63. BMW directs it to workshop personnel as a supplement to training-school knowledge, so it is best suited to trained technicians and experienced rebuilders who have precision measuring equipment and access to the specified tools. Routine inspection work is included, but the repair depth extends well beyond scheduled oil, filter, spark-plug, valve-clearance, Poly-V-belt, clutch, brake, and throttle-synchronization service.

Engine and Drivetrain Variants

The technical data distinguish the 848 cc R 850 engine from the 1085 cc R 1100 and separate RS/RT specifications from GS/R applications. The manual also identifies revised valve, guide, and seat data from the 1996 model year and a changed Hall-effect rotor/belt-pulley installation from 1995.

The R 1100 RS gearbox tables separate the 1993 transmission from the 1994-on M94 version, while the overhaul chapter provides different shaft-removal and shimming methods for conventional and Clean Bearing builds. Clean Bearing input-shaft conversion breaks are listed by gearbox number for the DAF, DAH, DAK, DAL, DAG, DAJ, DCF, and DCH sequences; full-conversion breaks are identified for DAQ through DAV and for DCQ/DCR units. This helps prevent parts or procedures from being selected for the wrong internal build.

Chassis, Brakes, and Electrical Scope

Model-specific chapters account for RS, RT, GS, and R differences in fairings, windshields, frames, center stands, footrests, steering components, wheels, brake layouts, instruments, and lighting. ABS coverage includes component removal and installation, hydraulic lines and bleeding, relay-base service, and front/rear sensor setting. The electrical material provides central electrical-box layouts, fuse assignments, and left/right harness-routing views for RT, RS, and GS models. It does not include full circuit schematics or a Motronic fault-code diagnostic chapter.

BMW warns that striking a Clean Bearing shaft seat can displace or damage the bearing, and that hammering the rear-drive pinion nut can damage the splines. These jobs rely on the specified pullers, sleeves, measuring fixtures, torque-angle procedures, and shim calculations rather than improvised assembly. Brake-hydraulic, fuel-system, and engine/frame work also requires correct support, system isolation, and workshop safety practices.

Special Tools and Technical Illustrations

Referenced BMW tools include engine mount 11 0 630, clutch-housing holder 11 5 640, ignition tester 12 3 650 with adapter lead 12 3 652, gearbox measuring plate 23 4 600, rear-drive measuring fixture 33 2 600 with measuring arm 33 2 604, and brake-piston setting tool 34 1 500.

Named visuals include the sectioned engine drawing, lubricating-oil circuit, cooling-oil circuit with oil thermostat, gearbox sectioned drawing, rear-wheel-drive sectioned drawing, and the model-specific wiring-harness views. Relay positions, fuse connections, frame and fairing views, and assembly illustrations support the written procedures. The manual applies to motorcycles in standard condition or fitted with genuine BMW accessories; modified configurations are outside its stated scope, and BMW identifies the separate Parts microfiches as the supplemental source for detailed parts illustrations.