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BMW R80 G S R80 GS MOTORBIKE Workshop Service Repair Manual
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๐ท๏ธ Basic Information Identification Make: BMW Model: R80 G/S Model Nickname: R80GS Vehicle Type: Motorcycle Generation Generation Code: Monolever Era Codes Engine Code Designation: Type 247 ๐ Introduction Market Position...
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๐ท๏ธ Basic Information
Identification
Make:
BMW
Model:
R80 G/S
Model Nickname:
R80GS
Vehicle Type:
Motorcycle
Generation
Generation Code:
Monolever Era
Codes
Engine Code Designation:
Type 247
๐ Introduction
Market Position
Segment:
Dual-sport / Adventure Motorcycle
Era Significance:
Pioneering the modern adventure motorcycle segment, combining off-road capability with on-road comfort and reliability.
Competitive Analysis
Competitors Of Era:
Honda Africa Twin (later models), Yamaha Tenere, Suzuki DR series, and other European dual-sports.
Key Features
Design Philosophy:
Robust, air-cooled boxer twin engine, shaft drive, long-travel suspension, and utilitarian design for versatility.
Innovation:
Introduction of the Monolever rear suspension system, simplifying the drivetrain and improving handling over earlier Paralever systems on some BMW models.
๐ Manual Details
Coverage Areas
Primary Coverage:
Workshop Service Repair
Included Systems:
Engine, Transmission, Chassis, Electrical, Fuel, Brakes, Suspension, Frame, Bodywork, Equipment
Page Count
Estimated Page Count:
Approx. 200-300 Pages (typical for this era's comprehensive manuals)
Manual Type
Type:
Comprehensive Workshop Manual / Service Manual / Repair Manual
Language
Language:
English (likely, standard for international markets)
Format
Format:
Digital (PDF likely, given product description format)
File Format:
PDF (Portable Document Format)
Print Quality:
High-resolution scans for clarity of text and diagrams, suitable for printing.
Binding Type:
N/A (Digital)
Paper Type:
N/A (Digital)
Searchability:
Likely fully searchable text within the PDF for quick information retrieval.
๐ Manual Coverage
Systems Covered
Engine System:
Detailed disassembly, inspection, and reassembly of the 785/798cc boxer twin engine, including cylinder head, pistons, crankshaft, camshafts, timing, lubrication system, and cooling (air).
Engine Electrical:
Ignition system (points/electronic), charging system (alternator, regulator), starter system, wiring diagrams, and component testing.
Fuel System:
Carburetor tuning and overhaul (likely Bing type), fuel pump operation, fuel tank and lines maintenance, and fuel filter replacement.
Exhaust System:
Inspection, repair, and replacement of exhaust headers, mufflers, and mounting hardware.
Clutch System:
Operation and maintenance of the dry single-plate clutch, clutch lever and cable adjustment.
Transmission:
Gearbox disassembly, inspection, lubrication, and troubleshooting. Includes gear selection mechanism.
Driveshaft:
Maintenance and inspection of the driveshaft, universal joint, and final drive splines.
Front Suspension:
Front fork (telescopic) disassembly, seal replacement, oil level and type specifications, and general inspection.
Steering System:
Steering head bearing adjustment, maintenance, and replacement. Handlebar inspection and tightening.
Rear Wheel Drive:
Monolever rear suspension system, including shock absorber adjustment and replacement, swingarm bearing inspection, and final drive hub maintenance.
Brake System:
Hydraulic front and rear brake systems, including caliper overhaul, master cylinder maintenance, brake fluid specifications, bleeding procedures, and pad replacement.
Pedal Assembly:
Brake and gearshift lever assembly inspection, lubrication, and adjustment.
Wheels Tires:
Wheel bearing inspection and replacement, spoke tensioning (if applicable to specific models), tire pressure recommendations, and basic wheel balancing procedures.
Frame System:
Frame inspection for damage, tightening of frame components, and mounting points for engine and suspension.
Equipment:
Includes items like the dual seat assembly (removal, installation, locking mechanism), luggage rack, and fairings (if equipped on certain variants).
General Electrics:
Comprehensive electrical system diagnosis, including battery maintenance, fuses, relays, switches, and wiring harness troubleshooting.
Instruments:
Speedometer, tachometer, indicator lights, and their electrical connections and functionality.
Light System:
Headlight, taillight, turn signals, and brake light operation, bulb replacement, and wiring.
Procedures Included
Maintenance:
Regular service tasks, lubrication points, fluid changes, filter replacements, chain adjustment (if applicable to specific variations), brake bleeding, and general inspection checklists.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides for common engine, electrical, and mechanical issues.
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly for virtually all mechanical and electrical systems.
Technical Specifications:
Torque values, clearances, fluid capacities, electrical resistance values, and other critical data required for accurate servicing.
Wiring Diagrams:
Detailed, often color-coded, electrical schematics for accurate diagnosis and repair of the electrical system.
Technical Depth
Depth:
Comprehensive: Covers everything from basic pre-ride checks and fluid top-ups to full engine rebuilds, gearbox overhauls, and electrical system diagnostics and repair.
โ๏ธ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, four-stroke, horizontally opposed twin-cylinder (Boxer)
Displacement Cc:
785 cc / 798 cc (depending on specific R80 G/S variant and bore/stroke configurations)
Bore X Stroke Mm:
Approx. 82.5 mm x 74.5 mm (for 798cc, consult manual for precise figures)
Compression Ratio:
Typically around 8.2:1 to 9.2:1 (varies by specific model and market)
Valve Train:
OHV (Overhead Valve) with pushrods and rockers
Cooling System:
Air-cooled
Performance
Horsepower Ps Hp:
Approx. 50-55 PS (37-40 kW) at 6,500 rpm (varies by specific model and tuning)
Torque Nm Lbft:
Approx. 57-62 Nm (42-46 lb-ft) at 4,000 rpm (varies by specific model and tuning)
Fuel System
Carburetion:
Dual Bing constant velocity carburetors (e.g., Bing 32/40/42)
Fuel Type:
Unleaded gasoline (petrol)
Fuel Capacity Liters Gallons:
Approx. 19-21 Liters (5.0-5.5 US gallons)
๐ง Transmission
Standard
Type:
5-speed constant mesh manual gearbox
Final Drive:
Shaft drive with universal joint and enclosed drive shaft
Features
Clutch Type:
Single dry plate, diaphragm spring
Gear Ratios:
Specific ratios will be detailed in the manual; typical for the era for good touring and off-road use.
Transmission Oil Type:
GL-5 SAE 80W/90 Hypoid Gear Oil (BMW recommended)
๐ Dimensions
Exterior
Length Mm:
Approx. 2200 mm (varies slightly by model year)
Width Mm:
Approx. 800 mm (handlebar width)
Height Mm:
Approx. 1300 mm (seat height varies)
Weights
Dry Weight Kg:
Approx. 185-195 kg (408-430 lbs)
Gross Vehicle Weight Rating Kg:
Approx. 380-400 kg (838-882 lbs)
๐ก๏ธ Safety Features
Ratings
Safety Certification:
Certified to relevant national and international motorcycle safety standards of the period.
Active Features
Brakes:
Dual disc front brake, single disc rear brake (hydraulic actuation) providing strong stopping power.
Suspension:
Long-travel telescopic front fork and Monolever rear suspension designed for stability and compliance over varied terrain.
Passive Features
Chassis Construction:
Strong steel tube frame providing rigidity and rider protection in typical falls.
๐ก Technology Features
Infotainment
Features:
Basic instrumentation: speedometer, tachometer, odometer, trip meter, neutral indicator, oil pressure light, turn signal indicators.
Driver Assistance
Features:
None in the modern sense; focused on mechanical reliability and rider input.
๐ง Maintenance
Service Intervals
Oil Change Interval Km Miles:
Typically every 5,000-10,000 km (3,000-6,000 miles) or annually, depending on usage. Consult manual for exact intervals.
Valve Clearance Check Km Miles:
Every 10,000-20,000 km (6,000-12,000 miles). Manual will specify precise figures.
Spark Plug Replacement Km Miles:
Every 10,000-15,000 km (6,000-9,000 miles). Specific plug types and gaps in manual.
Fluid Specifications
Engine Oil Type:
API SG/SH or higher, SAE 20W-50 or 10W-40 (depending on climate). BMW recommended specific oils. Manual specifies exact type and quantity.
Brake Fluid Type:
DOT 4 hydraulic fluid (minimum)
Fork Oil Type:
Specific suspension fluid (e.g., SAE 15W), quantity and level specified in manual.
Known Issues
Common Wear Items:
Clutch plates, universal joint, driveshaft splines, fork seals, head bearings, ignition points (on older models).
Potential Problems:
Carburetor tuning drift, electrical connector corrosion, charging system issues if not maintained.
๐ Vehicle History
Brand Heritage
Brand Legacy:
BMW Motorrad, renowned for engineering excellence, durability, and pioneering motorcycle technology since the early 20th century.
Model Evolution
Predecessors:
Successor to earlier R80 models, with the G/S designation (Gelรคnde/Straรe - Off-road/Street) marking a significant shift towards adventure touring.
Production Years:
The R80 G/S was produced from 1980 to 1987.
Successor Models:
The R80 G/S paved the way for the R100GS and subsequent GS series models which became iconic in the adventure touring market.
Production
Manufacturing Location:
Berlin, Germany
๐ Awards & Recognition
Recognitions
Market Impact:
Widely recognized for its durability, off-road capability, and suitability for long-distance travel, establishing BMW as a leader in the adventure motorcycle segment.