1999–2005 BMW R 1100 S Service & Repair Manual

BMW’s repair manual covers 1999–2005 BMW R 1100 S motorcycles, including ABS-equipped versions, in standard condition or fitted with genuine BMW accessories. This edition is marked 06/99.

Searchable Text and Procedure Bookmarks

Search and illustration detail: Workshop text is searchable, and embedded PDF bookmarks link to construction groups and individual procedures. Small callouts in the relay-location drawing are easier to read when enlarged.

Supplied as one printable, English-language 302-page PDF, including eight preliminary pages and 45 chapter spacer pages carrying only page numbers and chapter icons. The preliminaries contain the original cover, publishing information, introduction, contents, maintenance and pre-delivery check sheets, and one blank page. All are already included in the total.

Engine Rebuilding, Motronic Checks and Driveline Service

These selected topics cover part of the manual’s workshop content. Other procedures include instrument-panel disassembly and headlight adjustment.

• Engine repair: Engine removal, cylinder-head rebuilding, piston and cylinder inspection, crankshaft bearing measurements, oil-pump service, and valve-timing setup.

• Fuel and engine management: Motronic MA 2.4 component replacement, throttle-valve synchronization, fuel-pump pressure testing, and in-tank fuel-filter replacement.

• Clutch and gearbox: Dry-plate clutch replacement, hydraulic bleeding, gearbox disassembly, shaft inspection, selector adjustments, and shim selection.

• Suspension and final drive: Telelever fork and leading-link service, swingarm bearings, input bevel pinion rebuilding, crown-wheel backlash, and bearing preload.

• Brakes and ABS: Caliper rebuilding, disc inspection, brake bleeding, ABS sensor-gap adjustment, and ABS unit and relay replacement.

• Engine electrics: Hall-effect transmitter service, ignition timing, alternator and starter disassembly, electrical checks, and Poly-V belt tensioning.

Written for workshop personnel supplementing BMW training, this manual assumes practical repair knowledge and access to the specified diagnostic equipment and special tools.

Engine Inspection and Assembly

The engine chapter provides step-by-step procedures for cylinder-head disassembly, valve-guide replacement, crankcase separation, and reassembly. It distinguishes work possible with the engine installed from crankshaft, auxiliary-shaft, and timing-chain work requiring engine removal.

An engine cutaway drawing, lubricating-oil circuit schematic, and cooling-oil circuit diagram support the mechanical procedures. Component-specific torque tables include the staged cylinder-head and crankcase tightening requirements; the table of consumables identifies specified lubricants, sealants, and retaining compounds.

Motronic, Fuel Delivery and Charging

Maintenance coverage includes BMW MoDiTeC fault-memory reading, engine oil and filter changes, gearbox oil service, and intake-air-filter replacement. Throttle synchronization is documented alongside cable adjustment and the relevant test equipment.

The fuel-pressure test connects a measured result with checks of the pump, filter, regulator, and fuel lines, helping technicians narrow down a low-pressure problem before choosing components to replace. Several electrical checks rely on BMW MoDiTeC and its tester instructions.

Separate alternator procedures distinguish the standard Denso unit from the optional Bosch unit. Ignition coverage includes the Hall-effect transmitters, trigger-plate installation, and timing checks.

Gearbox and Rear-Drive Rebuilding

Internal gearbox coverage extends to input- and output-shaft disassembly, gear endplay, assembled shaft lengths, and selector-drum shimming. BMW guide pins 23 1 820 and measuring stand 23 4 761 are identified in the relevant procedures.

Incorrect handling during output-shaft disassembly or assembly can damage the needle roller bearing as it passes over the splines. The rear-drive chapter separately covers input bevel pinion bearings, crown-wheel tooth-contact patterns, and housing-cover shimming.

Telelever, ABS and Electrical Layouts

Front-fork and swingarm procedures identify heating limits for Loctite 2701-secured connections. Chassis coverage also includes steering controls, wheel bearings, frame removal, and wheel-track measurement.

ABS coverage concerns bleeding, sensors, unit removal and installation, and relay service. The manual requires ABS-unit work to be performed by an authorized BMW workshop. Its relay-socket warning explains that breaking the connected cable can require replacement of the complete ABS unit.

Electrical illustrations include relay positions in the central electrical equipment box and wiring-harness views from the left and right. These show physical routing and component locations rather than circuit-level wiring schematics.

Always ensure the motorcycle is properly secured on a stable stand or professional lift before beginning physical work.

A Preview of Valve Clearances and Final-Drive Backlash

Valve-clearance specifications distinguish intake clearance of 0.15 mm from exhaust clearance of 0.30 mm, both with the engine cold at a maximum of 35 °C (95 °F). The maintenance and engine-assembly sections describe the associated inspection and adjustment.

For the rear drive, crown-wheel backlash is specified at 0.07–0.16 mm, checked without oil. The chapter pairs this specification with a dial-gauge setup and shim-selection guidance.