Engine Code General:
Air-cooled, Boxer-twin cylinder
Chassis Codes:
R80/7, R90/6, R100/7, R100S, R100RT, R100RS, R100GS, R100R (Note: Specific model variations exist, and 1996 typically refers to the R100R and R100GS models in later production runs, though the manual may cover a broader range of the R series airheads that were still supported and serviced).
Market Segment:
Classic / Vintage Motorcycle, Adventure Touring (GS models), Standard/Sport Touring (RT, RS, S models).
Competitors:
Honda Gold Wing, Yamaha FJ/XJ series, Kawasaki Z series, Moto Guzzi California series.
Unique Selling Points:
Iconic boxer engine, shaft drive, robust construction, touring capability, enduring design, strong community support.
Manual Value Proposition:
Essential for owners seeking to maintain, repair, and preserve these legendary BMW airhead motorcycles, offering factory-level technical guidance.
Coverage Scope:
All models, engines, trims, and transmissions for the specified BMW R series airhead motorcycles produced around the 1996 model year, with potential extension to earlier compatible models.
Page Count:
Estimated 500-800+ pages (typical for comprehensive workshop manuals of this era).
Manual Type:
Workshop Repair Service Manual
Engine Service:
Engine overhaul, top-end repair (cylinder heads, valves, pistons), bottom-end repair (crankshaft, connecting rods, bearings), timing chain/sprocket replacement, oil pump, oil circulation system.
Fuel System:
Carburetor disassembly, cleaning, adjustment, and synchronization (e.g., Bing CV carburetors); fuel injection system troubleshooting and components (if applicable to specific 1996 R100 variants, though less common than carburetors); fuel tank, fuel pump, fuel lines.
Transmission Drivetrain:
Gearbox disassembly, inspection, and repair; clutch replacement and adjustment; final drive unit inspection and service; driveshaft and U-joint maintenance.
Electrical System:
Ignition system (points, electronic ignition, coils, spark plugs); charging system (alternator, regulator/rectifier); starting system (starter motor, solenoid); lighting system (headlight, taillight, indicators); wiring diagrams, component testing, troubleshooting.
Braking System:
Hydraulic brake system service (master cylinders, calipers, brake lines, brake fluid replacement); drum brake service (rear); troubleshooting brake fade, leaks, and performance issues.
Suspension Steering:
Front fork service (oil change, seal replacement, internal components); rear shock absorber inspection and replacement; steering head bearing adjustment and replacement; wheel bearing service.
Frame Bodywork:
Chassis inspection; fairing and body panel removal/installation; seat maintenance; kickstand and center stand service.
Preventative Maintenance:
Scheduled maintenance checks, lubrication points, filter replacement intervals, spark plug replacement, valve clearance adjustment.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, fault code interpretation (if applicable), electrical troubleshooting charts.
Repair Rebuild:
Detailed step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly, including torque specifications.
Special Tools:
Identification and usage of BMW-specific tools required for certain procedures.
Depth Of Coverage:
Comprehensive: Covers everything from basic rider maintenance and fluid checks to complete engine and transmission overhauls, electrical system diagnostics, and chassis component refurbishment.
Engine Type:
Air-cooled, four-stroke, horizontally opposed twin-cylinder (Boxer).
Bore Stroke R80:
Approx. 82 mm x 74.6 mm
Bore Stroke R90:
Approx. 90 mm x 70.6 mm
Bore Stroke R100:
Approx. 94 mm x 70.6 mm
Displacement R80:
797.5 cc
Displacement R90:
897.9 cc
Displacement R100:
979.9 cc (R100), 1047.2 cc (R100RT/RS often had a slightly larger bore variant)
Horsepower R80:
Approx. 50-55 hp @ 7000 rpm
Horsepower R90:
Approx. 65-70 hp @ 7000 rpm
Horsepower R100:
Approx. 65-75 hp @ 7000 rpm (varies by model, e.g., R100GS approx. 65 hp, R100RT approx. 70 hp)
Torque R100:
Approx. 70-75 Nm (51-55 lb-ft) @ 5000-6000 rpm
Carburetion:
Twin Bing constant velocity (CV) carburetors, typically 32mm or 40mm depending on model and year.
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2. Octane rating requirements may vary by specific engine tune and compression ratio.
Fuel Capacity:
Typically 17-21 liters (4.5-5.5 US gallons) depending on tank size and model.
Transmission Type:
5-speed manual gearbox, constant mesh.
Optional Transmission:
N/A (No automatic or alternative transmissions offered).
Drive Type:
Shaft drive to rear wheel.
Clutch Type:
Single dry plate, diaphragm spring clutch (operated by cable).
Wheelbase:
Varies by model, typically around 1450-1500 mm (57-59 inches).
Seat Height:
Varies by model, typically around 780-820 mm (30.7-32.3 inches).
Dry Weight:
Varies significantly by model and accessories, generally between 195-230 kg (430-507 lbs).
Gross Vehicle Weight:
Approximately 370-400 kg (815-882 lbs).
Safety Ratings:
N/A (Motorcycle safety ratings were not standardized or widely published in the same way as automobiles during this era).
Braking System Front:
Dual disc brakes (most R100 models), single disc (some R80/R90) with hydraulic actuation.
Braking System Rear:
Single disc brake (most models) or drum brake (earlier models) with hydraulic actuation.
Frame Construction:
Steel tube frame (double cradle).
Lighting:
Halogen headlight, integrated turn signals.
Oil Change Interval:
Typically every 5,000-10,000 km (3,000-6,000 miles) or annually, depending on usage and manufacturer recommendation. The manual will provide precise intervals.
Valve Clearance Interval:
Typically every 10,000 km (6,000 miles) or annually. This is a critical maintenance item for boxer engines.
Spark Plug Replacement:
As specified in manual, often around 10,000-20,000 km (6,000-12,000 miles).
Engine Oil Type:
Multi-viscosity oil, typically 20W-40 or 20W-50 API SG or higher. Manual will specify exact grade and API rating.
Engine Oil Capacity:
Approx. 2.5-3.0 liters (2.6-3.2 US quarts) for most models, with filter change. Manual will confirm.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify.
Transmission Oil Type:
Gear oil, typically SAE 80W-90 GL-5. Manual will confirm.
Final Drive Oil Type:
Gear oil, typically SAE 80W-90 GL-5. Manual will confirm.
Common Wear Items:
Clutch wear, fork seals, steering head bearings, rear shock absorber degradation, starter motor brushes, alternator output on older models.
Engine Specific Notes:
Carbon buildup in heads, valve guide wear, potential for oil leaks from various seals (e.g., crankshaft seals, oil pan gasket).
Electrical Quirks:
Failing voltage regulator/rectifier units, brittle wiring insulation over time, issues with the side stand switch.
Bmw Motorcycle Legacy:
BMW's long-standing reputation for engineering excellence, durability, and innovative motorcycle design dating back to the early 20th century.
R Series Airhead Lineage:
The R80, R90, and R100 models represent the evolution of BMW's air-cooled boxer-twin motorcycle platform, which began in the 1920s and saw continuous refinement through the 1970s and 1980s. The R100 series, particularly the GS and R models, were the pinnacle of this air-cooled era before the introduction of the oil-cooled and eventually liquid-cooled boxer engines.
Production Period:
The R100 series was produced from the late 1970s through the mid-1990s. While the manual specifies 1996, it likely covers the later iterations of the R100GS and R100R, which were the last airheads produced. Earlier R80 and R90 models span a wider range of years, and this manual may consolidate information across several related iterations.
Brand Awards:
BMW Motorrad consistently recognized for engineering quality, durability, and rider comfort, particularly in the touring segment.
Motorcycle Reviews:
These models, particularly the R100GS and R100RT, received critical acclaim for their capability, reliability, and suitability for long-distance travel and adventure riding during their production years.
Manual Certification:
N/A (As this is a reproduction/digital manual, not an official factory publication).
