BMW R 80 GS / R 100 GS/PD / R 100 R Repair Manual, 1978–1996

BMW Motorrad GmbH + Co., Service Department publication Repair Manual R 80 GS – R 100 R covers R 80 GS, R 100 GS/PD, and R 100 R. It distinguishes 1988 and 1991/Mod.91 procedures, Paris-Dakar equipment, and R 100 R-specific components. The information applies to standard-production motorcycles and machines fitted with Original BMW Accessories, without other modifications.

PDF Search, Diagram Detail and Page Layout

Search and navigation: PDF text search and embedded bookmarks are not available. Small terminal labels in electrical test diagrams and text in dense troubleshooting charts require zooming for comfortable reading.

One printable, English-language 168-page PDF, including one cover page and three introductory/contents pages. Many PDF pages show two original manual pages side by side.

Engine Overhaul, Electrical Diagnosis and Chassis Service

The following selected coverage highlights outline the main workshop areas rather than reproduce the full contents. Further topics include rear-frame removal and side-stand service.

• Maintenance and tuning: Factory inspection schedules, engine adjustments, carburetor synchronization, and routine fluid, filter, and battery service.

• Electrical diagnosis: Component tests and fault charts for ignition, charging, and starting problems, alongside alternator and starter repair.

• Engine overhaul: Step-by-step procedures for engine removal, cylinder-head repair, internal measurement, crankshaft work, and reassembly.

• Gearbox and clutch: Transmission teardown, shaft and bearing service, kick-start components, shift mechanisms, and clutch removal and installation.

• Rear-wheel drive: Pinion and crown-wheel bearing work, shimming, backlash measurement, tooth-contact checks, and swing-arm bearing adjustment.

• Brakes and suspension: Front hydraulic and rear drum brake repair, fork overhaul, steering-head and wheel bearings, spoke/rim service, and alignment checks.

The manual addresses workshop personnel and builds on service-school training; internal repairs assume familiarity with precision measurement and the specified BMW tooling.

Maintenance and Fuel-System Work

The schedules distinguish the 1,000 km inspection, inspections at 7,500 km and every additional 15,000 km, and service at 15,000 km and every additional 15,000 km. Separate BMW Maintenance and Inspection Schedule – Engine and Transmission and Running Gear charts organize the work.

Engine adjustments: Instructions cover cylinder-head nut retorque, rocker-arm end play, valve clearance, compression testing, spark-plug assessment, clutch play, and static and dynamic ignition timing. Air-filter replacement, fuel-cock cleaning, and battery maintenance are also documented.

Carburetors and emissions equipment: Disassembly extends to jets, float components, diaphragms, and throttle shafts. Synchronization procedures cover work with and without CO measurement, including PAS-equipped systems. The USA SHED section adds fuel/vent-valve service, troubleshooting, and the System Diagram of SHED Fuel System (USA).

Electrical Tests and Fault Tracing

Alternator/regulator and diode-plate checks are paired with starter tests using a voltmeter and ammeter. Other procedures cover ignition-coil resistance, relays, ignition-trigger service, carbon brushes, and removal of the engine, chassis, and rear wiring-harness sections.

Troubleshooting Ignition System and the alternator and starter fault charts connect symptoms to component checks, helping workshop users narrow a starting or charging fault before choosing a repair.

Headlamp and instrument procedures distinguish Paris-Dakar, 1991-model, and R 100 R hardware where required. Electrical coverage centers on component tests and fault finding; this edition does not contain a separate full wiring-diagram chapter.

Cylinder Heads, Crankshaft and Lubrication

Cylinder-head work includes valve inspection, valve-guide measurement, reaming and replacement, valve-seat correction, and valve installation. Piston/cylinder and connecting-rod measurements support internal inspection beyond routine maintenance.

Crankshaft and camshaft procedures cover main-bearing checks, bearing-bush replacement, end-play adjustment, and timing-chain work. The Report for Measuring Crankshaft Main Bearing Play provides a worksheet for recording measurements and calculating clearance. Oil-pump inspection and oil-cooler removal, disassembly, assembly, and installation are included.

Gearbox, Clutch and Rear-Wheel Drive

Gearbox setup: Internal work includes shaft disassembly, bearings, seals, shift discs, and the shift linkage. Shaft end-play measurement and spacer-ring calculation use measuring plate 23 3 650 with depth gauge 00 2 550. Troubleshooting addresses noise, difficult shifting, and gears that disengage.

Clutch work: Removal and installation cover the clutch housing, diaphragm spring, pressure plate, and disc, with alignment and balancing-mark requirements.

Final drive: Pinion and crown-wheel procedures extend to bearing replacement, taper-roller preload, backlash, and housing-cover shimming. Checking Tooth Contact Pattern illustrates the relationship between contact position and pinion shimming. Special-tool references include pin wrench 33 1 700.

The rear-drive instructions warn against contact at the pinion’s small-diameter end. They also identify shaft-seal damage during pinion-nut installation as a repair risk that can leave an oil leak.

Brakes, Forks and Wheel Service

Brake chapters distinguish GS and R 100 R front-caliper construction and cover master-cylinder repair, hydraulic lines, bleeding, rear brake shoes, and drum inspection. The front hydraulic brake uses DOT 4 fluid.

Fork procedures distinguish GS and R 100 R assemblies, including seals, sliding bushings, damper components, and stanchion/fork-bridge checks. Rear spring-strut work covers spring removal and mounting-eye components.

Wheel and chassis work includes spoke replacement, rim runout, static balancing, track alignment, and swing-arm bearings. Wheel-bearing tool references include internal extractor 00 8 573 with counter-support 00 8 570. The front-wheel bearing section cautions against heating the hub with the brake disc fitted, avoiding heat damage to the disc.

BMW notes that later repair instructions may be issued through Service Information. Brake hydraulics, heated hubs and housings, compressed fork springs, and engine/transmission removal require the workshop support and safety precautions specified in the manual.

Selected Chassis Limits and Intake-Valve Settings

The chassis tables specify rear spring travel of 180 mm for the GS models and 135 mm for the R 100 R. Maximum permissible track misalignment is 5 mm for the GS and 10 mm for the R 100 R.

For cold-engine valve adjustment at 20°C, intake clearance is 0.10 mm in normal service and 0.15 mm during running-in up to 1,000 km. Further tables cover tire and rim sizes, fork dimensions, final-drive ratios, electrical values, bearing fits, wear limits, and tightening torques.