BMW Motorcycle (R1100RT, R1100RS, R850/1100GS, R850/1100R). Manual - part 6

00.38

Checking/adjusting throttle syn-
chronisation and CO emission value

(Inspection I, II, III, IV)

•

[RT] Remove left side section of fairing.

•

Adjust wire cable for increased idle speed 
(choke).

Choke cable play:

.............................<

 1 mm (0.039 in)

•

Adjust the wire cable from the throttle twistgrip 
when the handlebar is on full right lock.

Throttle cable play:.......... app. 0.5 mm (0.0197 in)

•

Pre-adjust the wire connecting cable between 
the throttle stub pipes with the left or right ad-
justing screw .

•

Adjust the connecting cable to zero play.

RS130020

RS130030

RS130040

00.39

•

[RT] Remove the flap at the bottom of the right 
fairing.

•

Connect the BMW Synchrotester, 
BMW No. 13 0 800, to the vacuum 
bores in the throttle stub pipes. 

•

Ride the motorcycle until the engine is warm, or 
alternatively allow it to warm up at a standstill for 
approx. 10 minutes.

e

 Caution:

The engine must not run for more than 
20 minutes when the motorcycle is not moving.

Oil temperature:................................at least 90 °C
(FID: at least 5 bars)

•

Switch on the Synchrotester and select the bar 
chart display with maximum resolution..

L

 Note:

If the differences between the individual col-umns 
are very large (greater than 5 mm), switch to graph 
display and compare the cylinders; carry out fault di-
agnosis if necessary.

a

See BMW Synchrotester diagnosis instructions.

•

Rectify any faults found.

•

Set idle speed using recirculating air screws 
while maintaining synchronous running.

L

 Note:

Make sure that both throttle valves are closed.

Idle speed: ................................... 1000 

+

 

150 

min

-1

e

 Caution:

The sealed stop screws on the throttles must not be 
tampered with, or else the basic idle flow setting will 
have to be reset by the manufacturer.

RS130050

RS130060

00.40

With cable junction block

•

Push back the protective rubber cap (1) at the 
throttle and choke cables.

•

Turn adjusting screw (2) at the throttle and choke 
cables to adjust play.

Choke cable play: ................. app. 1 mm (0.039 in)
Throttle cable play:............... app. 1 mm (0.039 in)

•

Turn adjusting screws at the left and right throt-
tles to adjust play.

Throttle cable play:............. app. 2 mm (0.0787 in)

•

Connect the BMW Synchrotester, 
BMW No. 13 0 800, to the vacuum 
bores of the throttles.. 

•

Ride the motorcycle until the engine is warm,
or alternatively allow it to warm up at a 
standstill for approx. 10 minutes.

e

 Caution:

Engine must not run for more than 20 minutes when 
motorcycle is not moving.

Oil temperature: ...............................at least 90 °C
(FID: at least 5 bars)

•

Switch on the Synchrotester and select the bar 
chart with maximum resolution.

L

 Note:

If the differences between the individual 
columns are very large (greater than 5 mm), switch 
to graph display and compare the cylinders; carry 
out fault diagnosis if necessary.

a

See BMW Synchrotester diagnosis instructions.

1

2

RT000080

RT000070

00.41

•

Rectify any faults found.

•

Set idle speed using recirculating air screws 
while maintaining synchronous running.

Idle speed: ................................... 1000 

+

 

150 

min

-1

L

 Note:

Make sure that both throttle valves are closed.

e

 Caution:

The sealed stop screws on the throttles must not be 
tampered with, or else the basic idle flow setting will 
have to be reset by the manufacturer.

•

Carefully reduce play at the left throttle until the 
bar display on the Syncrotester changes.

•

Turn the adjusting screw until the bar display re-
verts to its original height.

•

Tighten the locknut.

L

 Note:

The height of the bar display must not change when 
the locknut is tightened.

•

Repeat this procedure at the right throttle

L

 Note:

If play is zero, the throttle butterflies may chatter.

•

Adjust throttle cable play at screws (1).

•

Push the protective rubber cap (2) back over the 
adjusting screw.

Throttle cable play:.......... app. 0.5 mm (0.0197 in)

•

Adjust choke cable to zero play at screw (1).

•

Push the protective rubber cap (2) over the ad-
justing screw.

•

Check the setting by turning the handlebar be-
tween the full right and left lock positions. Engine 
speed must not change during this check.

RT000070

1

2

RT000140

RS 11.055

2

1

RT000080

00.42

•

On motorcycles without catalytic converter 
make sure that the idle-speed CO content of the 
exhaust gas is in accordance with the nominal 
value and correct at the idle potentiometer if nec-
essary.

Idle-speed CO content: ............1.5 

± 

0.5

 (% by vol.)

•

Check synchronisation of throttles by opening 
them repeatedly but slowly up to an engine 
speed of app. 2500 rpm; the vacuum columns 
on the Synchrotester must drop together. Cor-
rect if necessary by turning the adjusting screws 
for the connecting cable.
When doing this, ensure that both throttles return 
to the limit position when closed.

L

 

Note:

Make sure that both throttle valves close against 
their stops when the throttle twistgrip is released.

•

Tighten locknuts and check synchronous run-
ning again.

•

Seal the vacuum bores.

Final inspection with road safety 
and functional check

(Inspection I, II, III, IV)

Road safety check

•

Check wheels and tyres.

•

Check/correct tyre pressures.

Tyre pressures:
Rider only.............................. front 2.2 bar(31.9 psi)

........................................... rear 2.5 bar (36.26 psi)

With pillion passenger ......... front 2.5 bar(36.26 psi)

............................................ rear 2.7 bar(39.16 psi)

With pillion passenger + luggage.............................

........................................... front 2.5 bar(36.26 psi)
............................................ rear 2.9 bar(42.06 psi)

Roadworthiness check

•

Lights

•

Telltale/warning lights

•

Horn

•

Instruments

•

Special equipment

•

Clutch

•

Gear shift

•

Steering

•

Foot brake and handbrake

•

If necessary, take motorcycle for a trial run.

RS130070

RS130080

11.1

Contents

Page

11

Technical Data

............................................................................................................................... 5

Sectioned drawing of engine 

...............................................................................................37

Lubricating oil circuit 

...............................................................................................................38

Coolant circuit 

..............................................................................................................................39

Cooling oil circuit (with oil thermostat) 

..........................................................................40

Removing engine 

........................................................................................................................41

Fitting auxiliary frame .........................................................................................................................52
Take off auxiliary frame. .....................................................................................................................53

Dismantling engine 

....................................................................................................................54

Removing cylinder head cover

 ................................................................................................55

Locking the engine in the TDC position

 ..............................................................................56

TDC on ignition stroke: ......................................................................................................................56

Removing and installing chain tensioner

 ............................................................................57

Assembly specification for timing chain tensioner:  ............................................................................57

Removing valve gear holder

 .....................................................................................................58

Dismantling/reassembling valve gear holder

 ....................................................................59

Removing cylinder head

 ............................................................................................................61

Dismantling, checking, repairing and re-assembling cylinder head

 ......................62

Removing and installing valves ..........................................................................................................62
Removing valve stem seals  ...............................................................................................................62
Checking valves for wear  ..................................................................................................................63
Remachining valve seat .....................................................................................................................63
Checking and repairing cylinder head  ...............................................................................................63
Checking valve guide for wear ...........................................................................................................63
Replacing valve guides ......................................................................................................................64
Installing valve and valve stem seal  ...................................................................................................65

Removing cylinder barrel

 ...........................................................................................................66

Removing/dismantling piston

 ..................................................................................................66

Checking pistons and cylinders

 .............................................................................................67

Assemble pistons

 .........................................................................................................................67

11 Motor

11.2

Contents

Page

Removing/installing conrod

 ......................................................................................................68

Removing and installing alternator cover with engine installed

 ...............................69

Removing alternator mount cover

 .........................................................................................69

Renewing radial shaft seal in alternator mount cover

 ...................................................70

Renewing radial shaft seal for rotary breather

 .................................................................70

Removing auxiliary-shaft drive

 ................................................................................................71

Removing oil pump

 ......................................................................................................................72

Oil temperature regulator

 ..........................................................................................................72

Removing radial shaft seal on crank-shaft with engine installed

 .............................73

Dismantling crankcase

 ...............................................................................................................74

Removing crankshaft, auxiliary shaft and timing chain tensioning and 
slide rails

 ...........................................................................................................................................76

Removing and installing oil pick-up basket

 .......................................................................77

Replacing oil level sight glass

 .................................................................................................77

Removing conrods

 .......................................................................................................................77

Checking conrods

 ........................................................................................................................77

Measuring main and big end bearing play

 .........................................................................78

easuring radial bearing play ...............................................................................................................78

Install main bearings

 ....................................................................................................................79

Measuring axial bearing play  .............................................................................................................79

Measuring big end bearing play

 .............................................................................................80

Assembling engine 

....................................................................................................................81

Installing conrod

 ............................................................................................................................81

Installing crankshaft

 .....................................................................................................................82

Installing timing chain tensioning and slide rails

 .............................................................82

Installing auxiliary shaft/timing chains

 ..................................................................................82

Assembling engine block

 ..........................................................................................................83

Installing radial seal on crankshaft

 ........................................................................................85

Installing clutch housing

 ............................................................................................................86

Installing oil pump

 .........................................................................................................................87

11.3

Contents

Page

Installing auxiliary shaft drive

 ...................................................................................................88

Installing pistons

 ............................................................................................................................89

Installing cylinders

 ........................................................................................................................90

Installing cylinder head

 ...............................................................................................................91

Adjusting valve clearances

 .......................................................................................................92

Installing right cylinder head

 ....................................................................................................93

Adjustment specification  ...................................................................................................................93

Installing left cylinder head

 .......................................................................................................94

Adjustment specification  ...................................................................................................................94

Installing alternator mount cover

 ............................................................................................96

Installing magnetic gate/belt pulley

 ......................................................................................96

Timing the ignition  .............................................................................................................................97

Installing alternator

 .......................................................................................................................98

Installing engin 

............................................................................................................................99