BMW R1100RT, R1100RS, R850GS/R1100GS, R850R/R1100R Service Manual (1994–1999)

BMW Motorcycle After Sales produced this R259 repair manual in Germany in February 2000. It covers the R1100RT, R1100RS, R850GS, R1100GS, R850R, and R1100R in factory configuration or with genuine BMW accessories.

Search, Bookmarks, and ZIP Contents

Text search and navigation: Workshop text and specification tables are searchable. Embedded bookmarks and a linked table of contents take you to chapters and procedures. Zoom in for fine connector and routing details in the illustrated harness views.

The ZIP contains one printable 464-page PDF. The total includes the original cover and imprint, the maintenance schedule, the pre-delivery checklist, the service data sheet, and 17 chapter layout pages with only a page number and section marker.

Boxer Overhaul, Drivetrain Setup, and ABS Service

Selected workshop topics are outlined below. The manual also shows how to check wheel track offset and remove model-specific exhaust assemblies.

• Boxer engine: Step-by-step engine removal and installation, with internal repair procedures for cylinder heads, valve gear, pistons, connecting rods, and crankshaft bearings.

• Clutch, gearbox, and final drive: Single dry-plate clutch centering, shaft and selector work, gearbox shimming with and without Clean Bearing, and BMW Paralever bevel-drive service.

• Fuel and Motronic MA 2.2: Throttle-body, injector, and air cleaner service, plus fuel filter, pump, and level sender replacement and a fuel-pressure test.

• Ignition, charging, and starting: Ignition-coil resistance checks, Hall-effect gate service and ignition timing, alternator and starter overhaul, and a starter-relay check.

• Brakes and ABS: Caliper overhaul, master-cylinder service, brake bleeding, ABS unit and relay-base work, and front and rear sensor-gap adjustment.

• Telelever, steering, and wheels: Fork and leading-link service, front and rear shock removal, steering cable and damper work, wheel-bearing replacement, static balancing, and spoke-wheel truing.

BMW directs the manual to workshop personnel as a reference alongside practical and theoretical service training.

Maintenance Schedules and Shop Data

The service schedule covers the 1,000 km inspection, 10,000 km service, 20,000 km inspection, and annual service. Group 00 ties Inspection I–IV to the work instructions and provides separate torque tables for RS/RT and GS/R models, plus capacities and approved lubricants. The front service data sheet lists five models. R850GS specifications are in the model-specific chapter tables.

The throttle procedures distinguish cable layouts with and without a junction block. BMW specifies the Synchrotester No. 13 0 800 for balancing and gives a separate idle CO check for models without a catalytic converter. Disturbing the sealed throttle stop screws changes the factory idle-air setting and requires a manufacturer reset.

Engine and Drivetrain Setup

The engine chapter shows the support fixtures and chassis separation involved in removal. It continues through valve-guide replacement, timing-chain and auxiliary-shaft work, oil-pump service, radial seal replacement, and internal measurements. The engine cross-section and the lubrication and thermostat-controlled oil circuit drawings show how those parts fit together. BMW identifies revised cylinder-head specifications from the 1996 model year and a different Hall-effect gate arrangement from 1995. The ignition timing procedure calls out TDC pin No. 11 2 650.

The R1100RS tables distinguish the 1993 gearbox and final drive from the 1994-on versions. Clean Bearing changeover numbers help identify which gearbox shimming procedure applies before shafts and bearings are measured. The gearbox cross-section accompanies the measuring-plate setup (BMW No. 23 4 600). Striking a Clean Bearing shaft can unseat the bearing from its locking ring and invalidate the measurement.

The rear-drive cross-section shows the relationship between the input bevel pinion and crown wheel. The chapter covers bearing preload, tooth contact, and backlash checks with BMW fixture No. 33 2 600. It also covers the driveshaft, universal joints, and rear swingarm.

Chassis, Bodywork, and Electrical References

The wheel chapter separates cast-wheel work from spoked-wheel centering and includes runout checks. The frame and equipment chapters cover RT and RS fairings and windshields, GS front bodywork and luggage rack, R rear trim, frame and rear-frame removal, stands, footrest plates, seats, and locks. Separate chapters cover instrument clusters and model-specific headlight removal and aiming.

The electrical chapter maps fuse and relay assignments, the ABS frame harness, and left- and right-side harness routing for the RT, RS, and GS. These drawings show physical routing and component locations. Pin-to-pin circuit tracing requires separate schematics. The alternator test calls for BMW diagnosis tester No. 61 1 510. BMW refers further Motronic and Synchrotester fault diagnosis to separate instructions and parts identification to its parts microfiches.

BMW's procedures specify secure support for engine removal and precautions for electrical isolation, fuel handling, and brake-fluid handling during the relevant work.

Sample Fuel, ABS, and Final-Drive Specifications

The fuel-pump check gives a nominal discharge-side pressure of 3 bar with the engine idling. The manual points to the pump, filter, regulator, and fuel line when pressure is low.

The rear ABS sensor procedures specify a gap of 0.45–0.55 mm at the marked point on the sensor wheel. The RS and GS/R/RT procedures use different runout checks to locate that point.

The rear-drive chapter specifies 0.07–0.16 mm of crown-wheel backlash when adjusting without oil. It covers tooth contact separately so both checks can be accounted for during setup.