Content .. 23 24 25 26 ..

BMW Motorcycle (R1100RT, R1100RS, R850/1100GS, R850/1100R). Manual - part 25

21.10

Adjusting clutch operating clear-
ance

•

Turn adjusting screw to obtain distance A.

Distance A:.................................. 12 mm (0.472 in)

•

[GS] If necessary, detach the hydraulic spring
adjusted with a 6 mm (0.24 in) Allen key,
BMW No. 31 5 600.

•

[RT] If necessary, detach the power socket
holder.

•

Using socket wrench, BMW No. 21 3 610,
loosen locknut (1) for adjusting screw (2) at
clutch release lever.

•

Set to distance B at the handlebar lever by turn-
ing adjusting screw (2) on the clutch release le-
ver.

Distance B: ................................... 7 mm (0.276 in)

Tightening torque:

Locknut on adjusting screw ......................... 22 Nm

RS210020

21 3 610

RS210030

RS210040

23.1

Contents

Page

Technical Data

............................................................................................................................... 3

Gearbox - sectioned drawing

................................................................................................7

Removing and installing clutch bear-ing/thrust rod/release lever

...................9

Removing and installing gear shift pedal

......................................................................10

Removing gearbox

.....................................................................................................................10

Dismantling/reassembling

.....................................................................................................12

Replacing shaft seal on neutral switch

................................................................................12

Removing gearbox cover

..........................................................................................................13

Removing selector drum

............................................................................................................14

Removing gearbox shafts

.........................................................................................................15

Removing and installing input shaft sealing ring at housing end

............................15

Removing/dismantling/reassembling selector shaft

.....................................................16

Removing and installing detent lever  .................................................................................................17
Removing and installing shift pawls  ...................................................................................................17
Removing and installing torsion spring  ..............................................................................................17

Removing and installing selector shaft seal

......................................................................17

Removing deep-groove ball bearing from selector drum

...........................................18

Shimming selector drum ...................................................................................................................18

Removing taper roller bearing race from input shaft and roller bearing from
idler shaft

..........................................................................................................................................18

Installing deep-groove ball bearing on selector drum

..................................................19

Installing taper roller bearing race on input shaft and roller bearing for
idler shaft

..........................................................................................................................................19

Removing and installing deep-groove ball bearing and race/roller bearing for
idler shaft

..........................................................................................................................................20

Dismantling/reassembling input shaft

..................................................................................21

Disassembling/assembling input shaft (Clean Bearing)

...............................................23

23 Gearbox

23.2

Contents

Page

Dismantling/reassembling output shaft

...............................................................................25

Removing deep-groove ball bearing ..................................................................................................25
Removing spur gears ........................................................................................................................26
Installing spur gears ..........................................................................................................................27

Installing gearbox shafts

............................................................................................................29

Removing and installing output shaft seal

.........................................................................30

Installing selector shaft

...............................................................................................................31

Installing selector forks

...............................................................................................................32

Installing selector drum

..............................................................................................................32

Shimming gearbox shafts

..........................................................................................................33

Measuring shaft bearing play .............................................................................................................33
Measuring gearbox cover ..................................................................................................................34

Shimming the gearbox shafts (without Clean Bearing)

.........................................35

Example

.............................................................................................................................................35

Shimming the gearbox shafts (with Clean Bearing)

................................................35

Example

.............................................................................................................................................35

Removing and installing taper roller bearing race

..........................................................36

Checking friction coefficient of input shaft taper roller bearing

................................36

Installing gearbox cover

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

Removing and installing input shaft seal at housing cover end

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

Completing assembly of gearbox

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

Installing gearbox

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

23.3

Technical Data

R 1100 RS

Type of gearbox

5-speed gearbox with claw-action shift and
integral reaction damper for all gears

Type of selector mechanism

Pedal-operated lever and selector drum with
overshoot detent

Gear ratios

up to 1993 model year

1st gear

4,030

2nd gear

2,576

3rd gear

1,886

4th gear

1,538

5th gear

1,318

Gear ratios

from 1994 (gearbox No. .....M94)

1st gear

4,163

2nd gear

2,914

3rd gear

2,133

4th gear

1,740

5th gear

1,450

Oil grade (all the year round)

Brand-name SAE 90 hypoid gear oil, API
Class GL 5

Filling capacity

Initial filling

l (Imp. pints) 1.0 (1.76) (to lower edge of filler screw)

When oil is changed

l (Imp. pints) approx. 0.8 (1.408) (to lower edge of filler screw)

End float on idler shaft

mm (in) 0,05...0,15 (0.00196...0.0059)

End float on output shaft

mm (in) 0,05...0,15 (0.00196...0.0059)

End float, input shaft (Clean Bearing)

mm (in) 0,05...0,15 (0.00196...0.0059)

Preload on input shaft

0.2 mm (0.00787) = 0.5...1.0 Nm frictio

End float at selector drum/deep-groove ball
bearing

mm (in)

0,1 (0.0039)

End float at deep-groove ball
bearing/housing

mm (in)

0,1 (0.0039)

Input-shaft conversion to
Clean Bearing

As of gearbox No.
10483 DAF
10776 DAH
12958 DAK
12650 DAL
12405 DAG
7864 DAJ
131 DCF
101 DCH

Full conversion to Clean Bearing
BMW No.: 2.325.222...227

As of gearbox No.
101 DAQ
101 DAR
101 DAS
101 DAT
101 DAU
101 DAV
101 DCQ
101 DCR

23.4

Technical Data

R 1100 RT

Type of gearbox

5-speed gearbox with claw-action shift and
integral reaction damper for all gears

Type of selector mechanism

Pedal-operated lever and selector drum with
overshoot detent

Gear ratios

from 1994
(gearbox No. .....M94))

1st gear

4,163

2nd gear

2,914

3rd gear

2,133

4th gear

1,740

5th gear

1,450

Oil grade (all the year round)

Brand-name SAE 90 hypoid gear oil, API
Class GL 5

Filling capacity

Initial filling

l (Imp. pints) 1.0 (1.76) (to lower edge of filler screw)

When oil is changed

l (Imp. pints) approx. 0.8 (1.408) (to lower edge of filler screw)

End float on idler shaft

mm (in)

0,05...0,15
(0.00196...0.0059)

End float on output shaft

mm (in)

0,05...0,15
(0.00196...0.0059)

End float, input shaft (Clean Bearing)

mm (in)

0,05...0,15
(0.00196...0.0059)

Preload on input shaft

0.2 mm (0.00787)
= 0.5...1.0 Nm frictio

End float at selector drum/deep-groove ball
bearing

mm (in)

0,1 (0.0039)

End float at deep-groove
ball bearing/housing

mm (in)

0,1 (0.0039)

Input-shaft conversion to
Clean Bearing

As of gearbox No.
10483 DAF
10776 DAH
12958 DAK
12650 DAL
12405 DAG
7864 DAJ
131 DCF
101 DCH

Full conversion to Clean Bearing
BMW No.: 2.325.222...227

As of gearbox No.
101 DAQ
101 DAR
101 DAS
101 DAT
101 DAU
101 DAV
101 DCQ
101 DCR

23.5

Technical Data

R 850 GS

R 1100 GS

Type of gearbox

5-speed gearbox with claw-action shift and
integral reaction damper for all gears

Type of selector mechanism

Pedal-operated lever and selector drum with
overshoot detent

Gear ratios

1st gear

4,163

2nd gear

2,914

3rd gear

2,133

4th gear

1,740

5th gear

1,450

Oil grade (all the year round)

Brand-name SAE 90
hypoid gear oil, API
Class GL 5

Filling capacity

Initial filling

l (Imp. pints) 1.0 (1.76) (to lower edge

of filler screw)

1.0 (1.76) (to lower edge
of filler screw)

When oil is changed

l (Imp. pints) approx. 0.8 (1.408) (to

lower edge of filler
screw)

approx. 0.8 (1.408) (to
lower edge of filler
screw)

End float on idler shaft

mm (in) 0,05...0,15

(0.00196...0.0059)

0,05...0,15
(0.00196...0.0059)

End float on output shaft

mm (in) 0,05...0,15

(0.00196...0.0059)

0,05...0,15
(0.00196...0.0059)

End float, input shaft (Clean Bearing)

mm (in) 0,05...0,15

(0.00196...0.0059)

0,05...0,15
(0.00196...0.0059)

Preload on input shaft

0.2 mm (0.00787)
= 0.5...1.0 Nm frictio

End float at selector drum/deep-groove ball
bearing

mm (in)

0,1 (0.0039)

End float at deep-groove
ball bearing/housing

mm (in)

0,1 (0.0039)

Input-shaft conversion to
Clean Bearing

As of gearbox No.
10483 DAF
10776 DAH
12958 DAK
12650 DAL
12405 DAG
7864 DAJ
131 DCF
101 DCH

Full conversion to Clean Bearing
BMW No.: 2.325.222...227

As of gearbox No.
101 DAQ
101 DAR
101 DAS
101 DAT
101 DAU
101 DAV
101 DCQ
101 DCR

23.6

Technical Data

R 850 R

R 1100 R

Type of gearbox

5-speed gearbox with claw-action shift and
integral reaction damper for all gears

Type of selector mechanism

Pedal-operated lever and selector drum with
overshoot detent

Gear ratios

1st gear

4,163

2nd gear

2,914

3rd gear

2,133

4th gear

1,740

5th gear

1,450

Oil grade (all the year round)

Brand-name SAE 90
hypoid gear oil, API
Class GL 5

Filling capacity

Initial filling

l (Imp. pints) 1.0 (1.76) (to lower edge

of filler screw)

1.0 (1.76) (to lower edge
of filler screw)

When oil is changed

l (Imp. pints) approx. 0.8 (1.408) (to

lower edge of filler
screw)

approx. 0.8 (1.408) (to
lower edge of filler
screw)

End float on idler shaft

mm (in) 0,05...0,15

(0.00196...0.0059)

0,05...0,15
(0.00196...0.0059)

End float on output shaft

mm (in) 0,05...0,15

(0.00196...0.0059)

0,05...0,15
(0.00196...0.0059)

End float, input shaft (Clean Bearing)

mm (in) 0,05...0,15

(0.00196...0.0059)

0,05...0,15
(0.00196...0.0059)

Preload on input shaft

0.2 mm (0.00787)
= 0.5...1.0 Nm frictio

End float at selector drum/deep-groove ball
bearing

mm (in)

0,1 (0.0039)

End float at deep-groove
ball bearing/housing

mm (in)

0,1 (0.0039)

Input-shaft conversion to
Clean Bearing

As of gearbox No.
10483 DAF
10776 DAH
12958 DAK
12650 DAL
12405 DAG
7864 DAJ
131 DCF
101 DCH

Full conversion to Clean Bearing
BMW No.: 2.325.222...227

As of gearbox No.
101 DAQ
101 DAR
101 DAS
101 DAT
101 DAU
101 DAV
101 DCQ
101 DCR

23.7

Gearbox - sectioned drawing

RS239010

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