BMW Oilhead_Maintenance

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Oilhead Maintenance ManualR850, R1100, R1150, R1200

Internet BMW Riders and Oilhead Riders

Edited by Carl Kulow

Send comments/corrections to kulowc@indiana.edu

ISBN R-850-1100-1150-1200 Third Edition 2-25-02 Copyright: IBMWR and Oilhead Riders

The authors have done their best to produce accurate information. However, they assume no liability for any damage or injury caused by any errors or omissions in this manual. Use at your own risk.

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TABLE OF CONTENTS Section I by Carl KulowMAINTENANCE SCHEDULE.................................................................................................................................................6 PARTS AND TOOL LIST .......................................................................................................................................................7

Cold Engine and Drivetrain ProceduresALTERNATOR BELT.............................................................................................................................................................8 VALVE ADJUSTMENT ..........................................................................................................................................................9 SPARK PLUGS ....................................................................................................................................................................12 AIR FILTER ..........................................................................................................................................................................13 LUBE SIDESTAND AND CENTERSTAND .........................................................................................................................14 CLUTCH CABLE..................................................................................................................................................................14 BRAKE AND CLUTCH FLUID .............................................................................................................................................15 BRAKE PADS ......................................................................................................................................................................16 BATTERY INSPECTION ......................................................................................................................................................17 FUEL FILTER .......................................................................................................................................................................18 MISCELLANEOUS...............................................................................................................................................................19 SUMP GUARD REMOVAL ..................................................................................................................................................20 TEST RIDE ...........................................................................................................................................................................20

Hot Engine and Drivetrain ProceduresTHROTTLE BODY SYNC ....................................................................................................................................................21 ENGINE OIL AND FILTER CHANGE ..................................................................................................................................23 TRANSMISSION GEAR OIL CHANGE ...............................................................................................................................24 REAR WHEEL DRIVE GEAR OIL CHANGE ......................................................................................................................25 SUMP GUARD INSTALLATION ..........................................................................................................................................25

Other proceduresBRAKE PAD REPLACEMENT ............................................................................................................................................26 TIRE CHANGE .....................................................................................................................................................................28

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TABLE OF CONTENTS (CONTINUED) Section II by Various AuthorsROUTINE R1100 SERVICE - PAUL GLAVES.....................................................................................................................32 VALVE ADJUSTMENT - STEPHEN KARLAN ....................................................................................................................38 CLUTCH ADJUSTMENT - PAUL GLAVES.........................................................................................................................40 CLUTCH ADJUSTMENT - BOB GORMAN .........................................................................................................................41 BRAKE BLEEDING - STEPHEN KARLAN .........................................................................................................................42 CHANGING THE FUEL FILTER ON AN R1100RS - JON DIAZ .........................................................................................47 EXTRNAL FUEL FILTER MODIFICATION - ROB LENTINI ...............................................................................................49 SYNCHRONIZING R1100 THROTTLE BODIES - BOB GORMAN.....................................................................................53 THROTTLE BODY SYNC - JON DIAZ ................................................................................................................................54 THROTTLE BODY SYNCH - STEPHEN KARLAN ............................................................................................................56 THROTTLE POSITION SENSOR - BOB GORMAN............................................................................................................60 THROTTLE POSITION SENSOR - ROB LENTINI ..............................................................................................................61 THROTTLE SCREW AND TPS ADJUSTMENT - STEPHEN KARLAN ............................................................................62 THROTTLE CABLE AND CHOKE CABLE REPLECEMENT - BRYAN LALLY ................................................................69 MOTRONIC FAULT CODES -STEFAN HEGNAUER..........................................................................................................71 LED FAULT CODE READER - HENRY DE KUIJER ..........................................................................................................73 ANALOG FAULT CODE READER - ROB LENTINI............................................................................................................73 DRIVESHAFT AND CLUTCH SPLINE LUBE - KIT VERCELLA ........................................................................................74

Section III - Super Tuning! by Rob LentiniZERO = ZERO THROTTLE POSITION SENSOR TUNING ...............................................................................................79 ADVANCED IGNITION TIMING ...........................................................................................................................................81 VALVE LASH INCREASE....................................................................................................................................................82 RESULTS OF INCREASED VALVE LASH AND ADVANCED TIMING .............................................................................82 NON-OEM PLUGS FOR THE R1100/850 OILHEADS ........................................................................................................83 THROTTLE BODY BUTTERFLY BUSHING/SEAL WEAR.................................................................................................85 GS INTAKE MANIFOLDS AND CAT CODE PLUG HOP UP AN R1100RS/RT...............................................................86

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IntroductionThere are three main sections to this manual as follows:

Section I by Carl KulowThis section consists of basic maintenance procedures that were done on an R1150GS, 2001. Once you remove the various plastic covers from an R, RT or RS, the procedures should essentially be identical to those given here.

Section II by Various AuthorsGenerally, this section contains more detailed instructions than those found in Section I, especially Stephen Karlans very detailed write-ups. This section also contains procedures that are not part of the normal maintenance schedule.

Section III by Rob LentiniThis section is the real masterpiece of this manual, containing Rob Lentinis Zero = Zero surging fix and other gems.

Note to RT and RS Riders: for many of the following procedures, you will need to remove the side panels as described in your owners manual Service and Technical Booklet except RT: instead of pulling the mirror off as the manual says, hold the back of the mirror (front of bike) with one hand while you hit the front outside corner of the mirror with the palm of your hand thus knocking the mirror off. Note: When performing maintenance on your bike, be sure that you consult multiple sources of information such as your owners manual, www.ibmwr.org/, and the various bike specific lists. Haynes, Clymer, and BMW have maintenance manuals with pictures and instructions that are invaluable get one of each for your bike.

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Service Every 6K MilesEngine oil and filter - change

Brake fluid check Brake pads check Clutch fluid check Sidestand grease Sidestand switch check Spark plugs check Valves adjust Throttle cables check Throttle Bodies - synchronize

Inspection Ev