Segment:
Dual-sport motorcycle, known for its reliability and off-road capability.
Competitors:
Honda Africa Twin (XRV650/750), Yamaha Tenere (XT600Z), Kawasaki KLR650, Suzuki DR650.
Design Philosophy:
Robust, air-cooled boxer twin engine, shaft drive, durable construction, excellent range for adventure touring.
Completeness:
Provides the most comprehensive information available for DIY mechanics and professional technicians working on this specific model range.
Covered Model Years:
1991, 1992, 1993, 1994, 1995, 1996
Covered Engine Variants:
R 80 GS (Airhead boxer engine)
Estimated Page Count:
400+
Type:
Comprehensive Service and Repair Manual
Format:
Digital (likely PDF, potentially with printable pages)
Engine:
Complete overhaul, disassembly, assembly, tuning, troubleshooting, lubrication, cooling system, fuel system (carburetors).
Transmission:
Gearbox (5-speed), clutch, drive shaft, final drive unit, maintenance, repair, troubleshooting.
Chassis And Frame:
Frame inspection, steering head bearings, swingarm, rear shock absorber replacement and adjustment, front fork overhaul and adjustment.
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator), ignition system (points, ignition coil, spark plugs), lighting, starter motor, troubleshooting.
Brakes:
Front and rear brake systems (disc brakes), hydraulic components, brake pad replacement, fluid flushing and bleeding, troubleshooting.
Fuel System:
Carburetor identification (e.g., Bing CV), disassembly, cleaning, adjustment, fuel tank, fuel lines, fuel pump (if applicable).
Exhaust System:
Exhaust pipe and muffler inspection, gasket replacement, tightening.
Wheels And Tires:
Wheel removal and installation, spoke tensioning, tire pressure recommendations, tire replacement.
Bodywork And Fairings:
Panel removal and installation, seat, fuel tank fairings, instrument cluster, headlight assembly.
Maintenance:
Scheduled maintenance, oil changes, filter replacements (oil, air), spark plug checks/replacement, valve clearance adjustment, carb synchronization, lubrication points.
Repair:
Engine rebuilds, transmission overhauls, brake caliper servicing, electrical component repair, suspension component replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault finding based on symptoms, electrical system diagnostics.
Technical Data:
Torque specifications for all fasteners, fluid capacities, component specifications, engine timings, electrical resistance values.
Depth:
In-depth mechanical and electrical repair, including full engine and transmission rebuilds, carburetor tuning, and advanced electrical troubleshooting.
Type:
Air-cooled, four-stroke, boxer twin-cylinder
Bore X Stroke:
90.0 mm x 62.0 mm
Valve Train:
Overhead camshaft (OHC), two valves per cylinder
Horsepower:
Approximately 50 hp @ 6,500 rpm
Torque:
Approximately 57 Nm (42 lb-ft) @ 5,000 rpm
Carburetors:
2 x Bing 32mm Constant Velocity (CV) carburetors
Fuel Type:
Unleaded gasoline (premium recommended)
Oil Type:
SAE 20W-50 or 10W-40 motorcycle-specific oil (refer to manual for exact specifications and change intervals).
Oil Capacity:
Approximately 3.0 liters (with filter change)
Ignition Type:
Contact breaker points and coil ignition
Crash Safety:
N/A (Motorcycle safety is primarily rider-dependent and vehicle design, not subject to car-like crash ratings).
Braking:
Dual disc front brakes, single disc rear brake with hydraulic actuation.
Suspension:
Telescopic front forks with adjustable preload/damping (depending on specific R 80 GS variant), Monolever rear swingarm with adjustable rear shock absorber.
Lighting:
Halogen headlight, tail light, brake light, turn signals.
Oil Change Interval:
Every 5,000 - 10,000 km or annually (refer to manual for precise interval based on usage).
Valve Adjustment Interval:
Every 10,000 - 20,000 km (critical for boxer engine performance).
Carburetor Sync Interval:
Every 10,000 - 20,000 km, or as needed if idle issues arise.
Spark Plug Replacement Interval:
Every 10,000 - 20,000 km, or as per manual recommendations.
Brake Fluid:
DOT 4 or DOT 5.1 (consult manual for exact type and change interval).
Final Drive Fluid:
Hypoid gear oil, GL-5, SAE 80W-90 (refer to manual).
Common Problems:
Worn clutch plates, output shaft seal leaks, charging system (stator/rotor/regulator) failures, ignition point wear, exhaust header leaks, swingarm bearing wear.
Troubleshooting Areas:
Carburetor idle stability, hard starting, erratic engine performance, electrical charging faults, brake fade.
