BMW R80 GS R100 R 1996 Service Repair Workshop Manual

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Tipo: Motorcycle

Proveedor:

SKU: 73581

Etiquetas: 1996 BMW Cars Misc Motorcycle R100 R R80 GS

Variantes de producto

Descripción

The BMW R80GS and R100GS models represent a significant chapter in motorcycle history, pioneering the dual-sport and adventure touring segment. Produced for the 1996 model year, these motorcycles are characterized by their robust, air-cooled boxer twin engines, known for their reliability and substantial torque, and a shaft drive system for low maintenance. Designed for both on-road comfort during long-distance touring and capability on unpaved surfaces, they offer a unique blend of performance and versatility. Their engineering quality and durability have cemented their status as iconic machines, capable of enduring extensive use. This comprehensive service repair workshop manual provides detailed guidance for the BMW R80GS and R100GS, covering all aspects of maintenance and repair. Within its pages, you will find in-depth instructions for engine overhaul, transmission service, fuel system maintenance, ignition system troubleshooting, and electrical system diagnostics. The manual also details procedures for suspension and steering, braking systems, wheel and tire service, exhaust systems, and frame and bodywork. It includes routine maintenance schedules, component rebuild instructions, and troubleshooting guides for common issues, empowering owners and technicians to effectively maintain and restore these celebrated motorcycles.

🏷️ Basic Information

Identification

Make:

Model:

R80GS / R100GS

Model Variant:

R80GS, R100GS

Year:

Codes

Chassis Codes:

247E (R80GS), 247B (R100GS)

👋 Introduction

Market Position

Market Segment:

Dual-sport / Adventure motorcycle

Competitive Analysis

Competitors:

Honda Africa Twin (XRV650/750), Yamaha Tenere, Kawasaki KLR650, Suzuki DR650.

Key Features

Design Philosophy:

Robust, air-cooled boxer twin engine known for reliability and torque; shaft drive; capable off-road and comfortable for touring.

📋 Manual Details

Coverage Areas

Comprehensive Coverage:

Yes, covers all aspects of service and repair for the specified models and year.

Page Count

Estimated Page Count:

300-500 (typical for comprehensive BMW motorcycle manuals of this era)

Manual Type

Manual Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete disassembly, inspection, repair, and reassembly of the boxer twin engine.

Transmission Service:

Gearbox disassembly, inspection, repair, and reassembly; clutch service and replacement.

Fuel System:

Carburetor (Dell'Orto or Bing) overhaul, adjustment, and troubleshooting; fuel tank and pump maintenance.

Ignition System:

Ignition timing, coil testing, spark plug specifications, and electronic ignition system troubleshooting.

Electrical System:

Wiring diagrams, battery maintenance, charging system (alternator, regulator), lighting, and starter motor.

Suspension And Steering:

Front fork (telelever or conventional) overhaul, rear shock absorber replacement, steering head bearing service.

Braking System:

Brake fluid replacement, caliper overhaul, pad replacement, disc inspection, and hydraulic system bleeding.

Wheel And Tire Service:

Wheel bearing replacement, spoke tensioning (if applicable), tire mounting and balancing.

Exhaust System:

Exhaust system inspection, gasket replacement, and muffler service.

Frame And Bodywork:

Frame inspection, fairing and body panel removal/installation, seat service.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, brake checks, spark plug checks.

Troubleshooting Guides:

Diagnostic procedures for common problems across all major systems.

Component Rebuilds:

Detailed instructions for rebuilding engines, transmissions, carburetors, and brake calipers.

Electrical Diagnostics:

Step-by-step troubleshooting using wiring diagrams and component testing methods.

Suspension Setup:

Adjustments and overhaul procedures for front and rear suspension components.

Technical Depth

Technical Depth:

Comprehensive, ranging from basic owner-level maintenance to in-depth professional workshop repairs and diagnostics.

📊 Manual Specifications

File Format

File Format:

Searchable PDF

Print Quality

Print Quality:

High-resolution scans, suitable for printing high-quality diagrams and text.

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, four-stroke, boxer twin

Engine Displacement R80:

797.5 cc

Engine Displacement R100:

980 cc

Bore X Stroke R80:

82.5 mm x 75 mm

Bore X Stroke R100:

94 mm x 70.7 mm

Compression Ratio R80:

8.2:1

Compression Ratio R100:

8.5:1

Horsepower R80 Approx:

50 hp @ 6500 rpm

Horsepower R100 Approx:

60 hp @ 6250 rpm

Torque R80 Approx:

56 Nm (41 lb-ft) @ 5000 rpm

Torque R100 Approx:

70 Nm (52 lb-ft) @ 5000 rpm

Fuel System

Carburetors R80:

2 x Dell'Orto PHM 40 or Bing 40

Carburetors R100:

2 x Bing 40

Fuel Tank Capacity:

20 Liters (5.3 US gal)

Fuel Type:

Unleaded gasoline, minimum 91 RON

🔧 Transmission

Standard

Transmission Type:

5-speed manual

Final Drive:

Shaft drive

Features

Clutch Type:

Single dry plate, diaphragm spring

Transmission Fluid Type:

SAE 80W-90 API GL-5 gear oil

Transmission Fluid Capacity:

Approx. 0.8 Liters

📐 Dimensions

Exterior

Length Approx:

2200 mm (86.6 in)

Width Approx:

890 mm (35.0 in)

Height Approx:

1370 mm (53.9 in)

Weights

Dry Weight R80 Approx:

215 kg (474 lbs)

Dry Weight R100 Approx:

225 kg (496 lbs)

Gvwr Approx:

430 kg (948 lbs)

Seat Height Approx:

850 mm (33.5 in)

🛡️ Safety Features

Ratings

Safety Certification:

ECE standards for motorcycles of the era

Active Features

Braking System Front:

Dual 285 mm discs with dual-piston calipers (e.g., Brembo or Grimeca)

Braking System Rear:

200 mm drum brake (early models) or single 285 mm disc with single-piston caliper (later models)

Passive Features

Lighting:

Halogen headlamp, integrated turn signals, taillight/brake light.

💡 Technology Features

Infotainment

Infotainment System:

N/A (classic motorcycle, no integrated infotainment)

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Options:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-10,000 km (3,000-6,000 miles) or annually, whichever comes first.

Valve Adjustment Interval:

Every 10,000 km (6,000 miles)

Final Drive Oil Change:

Every 10,000 km (6,000 miles)

Fluid Specifications

Engine Oil Type:

SAE 20W-50 or SAE 15W-50 API SG or higher (e.g., BMW Motorrad ADVANTEC)

Engine Oil Capacity Approx:

2.5 Liters (with filter change)

Brake Fluid Type:

DOT 4 (glycol-based)

Known Issues

Common Issues:

Worn output shaft seal, paralever pivot bearings, clutch slave cylinder leaks, starter motor brushes, fork seal leaks.

Carburetor Issues:

Float bowl leaks, synchronization drift, jet wear.

Electrical Issues:

Corrosion in connectors, failing voltage regulator, worn starter solenoid.

📚 Vehicle History

Brand Heritage

Brand Origin:

Bayerische Motoren Werke AG (BMW), Germany, founded 1916.

Model Evolution

Gs Series Heritage:

The R80GS and R100GS are part of BMW's legendary 'Gelände/Straße' (Off-road/Street) series, pioneering the adventure touring segment.

R80Gs Introduction:

Introduced in 1980, revolutionizing motorcycle travel with its robust design and dual-purpose capability.

R100Gs Introduction:

Introduced in 1987, building on the R80GS with a larger engine and updated features.

Production

Production Period:

R80GS: 1980-1987; R100GS: 1987-1996.

Manufacturing Location:

Berlin, Germany (BMW Motorrad plant)

🏆 Awards & Recognition

Recognitions

Adventure Pioneering:

Widely credited with establishing and popularizing the adventure touring motorcycle category.

Durability Reputation:

Renowned for their robust build quality and longevity, capable of high mileage with proper maintenance.