BMW R80 R90 R100 1978-1996 WSM Service Manual Repair

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🏷️ Basic Information Identification Make: BMW Model: R Series (R80, R90, R100) Codes Production Decades: 1970s, 1980s, 1990s 👋 Introduction Market Position Motorcycle Segment: Iconic touring and sport-touring motorcycles, known...

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类型: Motorcycle

斯库: 466902

标签: 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 BMW Cars Misc Motorcycle R100 R80 R90

产品多属性

Description

🏷️ Basic Information

Identification

Make:

Model:

R Series (R80, R90, R100)

Codes

Production Decades:

1970s, 1980s, 1990s

👋 Introduction

Market Position

Motorcycle Segment:

Iconic touring and sport-touring motorcycles, known for shaft drive, boxer engines, and durability.

Competitive Analysis

Competitors:

Honda GL series, Yamaha XS models, Kawasaki Z series (though often shaft-drive competition was limited in this specific niche).

Key Features

Engine Layout:

Air-cooled, horizontally opposed twin-cylinder (boxer) engine.

Drivetrain:

Shaft drive, eliminating chain maintenance.

Reliability:

Renowned for robust engineering and longevity when properly maintained.

Touring Capability:

Models like the R100RT and RS were designed for long-distance touring with fairings and comfortable ergonomics.

📋 Manual Details

Coverage Areas

Supported Models:

BMW R80, R90, R100 series motorcycles

Supported Years:

1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996

Page Count

Estimated Pages:

700-1000 (typical for comprehensive WSMs of this era, actual may vary)

Manual Type

Type:

Workshop Service Manual (WSM)

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete disassembly, assembly, overhaul, diagnostics, troubleshooting of air-cooled boxer twin engines (e.g., R80, R90/6, R100/7, R100RS, R100RT, R100GS, R100R)

Transmission:

5-speed gearbox: removal, disassembly, reassembly, lubrication, troubleshooting, common wear parts

Drivetrain:

Clutch (single dry plate), driveshaft, bevel gear drive unit: maintenance, inspection, repair

Fuel System:

Carburetor (Bing 32/40/48mm) overhaul, adjustment, synchronization; fuel tank maintenance, fuel lines

Ignition System:

Electronic ignition systems (breakerless), ignition timing, component testing, spark plugs

Electrical System:

Wiring diagrams, charging system (alternator, regulator), battery maintenance, lighting, starter motor, horn, instrumentation

Brakes:

Front and rear brake systems (disc and drum), hydraulic systems, fluid replacement, bleeding, caliper/master cylinder overhaul

Suspension:

Front telescopic forks (e.g., /7 series, Monolever, Paralever), rear swingarm, shock absorbers: maintenance, fluid changes, seal replacement, adjustment

Wheels Tires:

Wheel bearing maintenance, tire inspection and replacement, spoke wheel care

Frame Chassis:

Frame inspection, headstock bearing maintenance, general chassis integrity

Bodywork:

Fairings (e.g., RS, RT models), fuel tank, seat, fenders: removal, installation, minor repair considerations

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, valve clearance adjustment, spark plug replacement, drive shaft lubrication, brake checks, tire pressure checks

Troubleshooting:

Diagnostic charts for common running issues, electrical faults, starting problems, braking issues

Engine Rebuild:

Piston removal/installation, cylinder honing, crankshaft inspection, bearing replacement, gasket renewal

Electrical Diagnostics:

Testing stator coils, regulator, ignition module, starter solenoid, wiring harness continuity

Carburetor Tuning:

Synchronization of dual carburetors, idle speed and mixture adjustment

Brake System Overhaul:

Seal replacement in master cylinders and calipers, brake line flushing and bleeding procedures

Suspension Servicing:

Fork oil replacement, seal head replacement, rear shock absorber inspection and replacement

Technical Depth

Depth:

Comprehensive, suitable for home mechanics and professional technicians. Includes detailed step-by-step instructions, exploded diagrams, torque specifications, and diagnostic procedures.

📊 Manual Specifications

File Format

Quality:

High-resolution scans, clear text, searchable content

Print Quality

Scalability:

Optimized for digital viewing and printing of individual pages.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, four-stroke, horizontally opposed twin-cylinder (Boxer)

Bore X Stroke:

Varies by model (e.g., R80: 82.5mm x 74.5mm; R100: 94mm x 70.7mm)

Displacement:

Typically 798cc (R80), 971cc-999cc (R90/R100 variants)

Compression Ratio:

Varies by model (e.g., 8.5:1 to 9.5:1)

Valve Train:

OHV, two valves per cylinder, pushrod actuated

Cooling System:

Air-cooled

Performance

Horsepower:

Varies by model (e.g., R80: ~50-55 hp; R100: ~65-70 hp)

Torque:

Varies by model (e.g., R80: ~60 Nm; R100: ~75 Nm)

Fuel System

Carburetors:

Typically dual Bing constant-velocity carburetors (e.g., Bing 32/40/48mm)

Fuel Type:

Unleaded gasoline (91 RON or higher, though leaded was common in earlier years)

🔧 Transmission

Standard

Type:

5-speed constant mesh gearbox

Drive Type:

Shaft drive to rear wheel

Optional

Gearbox Variations:

Different gear ratios available depending on the specific model variant (e.g., GS models often had different final drive ratios).

Features

Clutch:

Single dry plate diaphragm spring clutch

Lubrication:

Gearbox oil shared with final drive on some earlier models; separate gearbox oil on later models. Manual specifies specific BMW gear oil.

📐 Dimensions

Exterior

Wheelbase:

Varies by model (approx. 1400-1460 mm)

Seat Height:

Varies by model (approx. 780-840 mm)

Weights

Dry Weight:

Varies by model (approx. 190-230 kg)

Fuel Capacity:

Varies by model (typically 17-24 liters)

🛡️ Safety Features

Ratings

Safety Standards:

Motorcycle safety standards of the era; no formal crash ratings like automobiles.

Active Features

Braking System:

Generally dual front disc brakes on higher-spec models (e.g., R100RS, R100RT, R100GS) and single rear disc or drum brake. Later models introduced ABS on some variants.

Passive Features

Frame Strength:

Robust steel tube frame construction.

💡 Technology Features

Infotainment

Features:

Basic instrumentation: speedometer, tachometer, odometer, warning lights. Some touring models had analog clocks and voltage meters.

Driver Assistance

Available as an option on some later R100 models (e.g., R100RT, R100GS Paris-Dakar), but not standard across the range.

Connectivity

Features:

N/A (No modern connectivity features).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 - 10,000 km or annually. Manual specifies exact interval and oil type.

Valve Adjustment Interval:

Every 10,000 - 20,000 km. Critical for performance and longevity.

Transmission Oil Change:

Typically every 20,000 - 40,000 km. Manual specifies interval and lubricant grade.

Fluid Specifications

Engine Oil Type:

API SG, SAE 20W-50 or 15W-50 recommended (check manual for specific recommendations based on climate).

Brake Fluid Type:

DOT 4 (or DOT 3 for older systems if specified). Regular flushing is crucial.

Fork Oil Type:

Type F automatic transmission fluid or specific motorcycle fork oil, with appropriate viscosity grade (e.g., SAE 5W or 10W).

Known Issues

Common Wear Items:

Valve guide wear, clutch wear, output shaft seal leaks, aging electrical connectors, output shaft splines (lubrication critical), starter clutch issues, swingarm bearing wear.

Electrical Gremlins:

Corrosion in wiring connectors, particularly around the ignition switch and rectifier wiring. Diode board issues on older models.

Engine Mounts:

Rubber engine mounts can degrade over time, affecting vibration isolation.

📚 Vehicle History

Brand Heritage

Bmw Motorcycle Legacy:

BMW has a long history of producing reliable and innovative motorcycles, particularly known for their boxer engines and shaft drive.

Model Evolution

R Series Development:

The R80, R90, and R100 models represent the evolution of BMW's air-cooled boxer platform, starting from the /5 series and progressing through /6, /7, R45/65, R80/100GS, and R100R variants.

Production

Manufacturing Location:

Berlin-Spandau, Germany

Key Variants Covered:

R80/7, R80G/S, R80ST, R80GS, R80R, R90/6, R90S, R100/7, R100S, R100CS, R100RS, R100RT, R100GS, R100R

🏆 Awards & Recognition

Recognitions

Industry Standing:

The R-series motorcycles of this era are widely regarded as benchmarks for durability, touring comfort, and enduring design. They have a cult following among enthusiasts.

Ratings

Expert Reviews:

Consistently praised in period road tests for their strong low-end torque, shaft drive convenience, and capable handling for their size and intended purpose.