BMW Motorcycle (R1100RT, R1100RS, R850/1100GS, R850/1100R). Manual - part 40

34.23

[GS/R/RT] Adjusting rear ABS sen-
sor gap

Marking sensor wheel

•

Before removing/installing, clean sensor and 
bore.

•

Using Torx T 25, detach the sensor.

•

Bolt dial gauge holder with measuring shoe, ex-
tension BMW No. 34 2 520 and dial gauge, 
BMW No. 00 2 510, to sensor mount.

•

Zero the dial gauge.

•

Measure axial runout over the entire circum-
ference.

•

Make a permanent paint pencil mark at the point 
where the sensor wheel is farthest away from the 
sensor (arrow).

e

 Caution:

If parts are replaced (rear wheel etc.) and a used or 
previously marked sensor wheel is installed, the 
sensor ring must be measured and marked again.
Remove the old marking.

Checking and adjusting sensor gap

•

Check/adjust at the marked point

•

If necessary, remove/install sensor with
Torx T 25 and adjust sensor gap with spacing 
plates.

e

 Caution:

After adjusting, check that the sensor wheel is free 
to turn at all points on its circumference.

Sensor gap:.. 0.45...0.55 mm (0.0177...0.02165 in)

X

 Tightening torque:

Sensor ...........................................handtight, 4 Nm

34 2 520

00 2 510

GS340181

34.24

Removing, installing, dismantling and 
assembling front brake master cylin-
der

•

Drain fluid from brake system.

e

 Caution:

Do not allow brake fluid to come into contact with 
painted parts of the motorcycle, because brake fluid 
destroys paint.

•

Remove cover (1).

•

Remove handbrake lever pivot pin (2).

•

Pull off dust protection sleeve (3).

•

Press piston (4) in slightly.

•

Slacken off stop screw (5).

e

 Caution:

Piston (4) is spring-loaded.

•

Take out piston (4) with spring (6).

•

Install in the reverse order of work.

•

Coat pistons and sleeves with brake fluid before 
installing.

e

 Caution:

Sealing lips of sleeves face the pressure chamber.

•

Fill/bleed the brake system.

Adjusting specification for handbrake lever

•

Clean grub screw (7), coat it with Loctite 270 
and screw it in until there is no play at the 
handlebar lever; then tighten it further by pre-
cisely one half-turn.

e

 Caution:

Never tighten the grub screw by more than this ad-
ditional half-turn, or else the brake could fail or be 
locked on.

•

Seal grub screw (7) with paint.

•

Grease thrust pin (arrow) at handlebar lever light-
ly with Shell Retinax A.

L

 Note:

The pivot pin is secured with Tuflok blue. Threads 
secured with this material can be un screwed and 
retightened several times.

X

 Tightening torque:

Pivot pin (2)  ................................................... 8 Nm
(Threads secured with Tuflok blue can be un
screwed and tightened several times.)

RS340110

2

5

1

7

4

6

3

34.25

Removing and installing rear brake 
master cylinder

•

Drain fluid from brake system.

e

 Caution:

Do not allow brake fluid to come into contact with 
painted parts of the motorcycle, because brake fluid 
destroys paint.

•

[RS/GS/R] Detach brake line (1) and hose (2).

•

[RS/GS/R] Release pin (3).

•

[RS/GS/R] Detach brake master cylinder (4).

•

[RT] Remove right side sections of fairing.

•

[RT] Detach brake line (1).

•

[RT] Release pin (3).

•

[RT] Detach brake master cylinder (4).

•

[RT] Remove brake fluid reservoir with hose (2) 
and master cylinder.

•

[RT] Detach hose (2) from master cylinder.

•

Install in the reverse order of work.

•

Tighten non-reusable hose clip (2) with pliers, 
BMW No. 13 1 500.

e

 Caution:

Bleed the brake system carefully.
Check/adjust piston rod snifting-action play.

X

 Tightening torque:

Master cylinder to footrest plate ..................... 9 Nm

Checking and adjusting relief clear-
ance of piston rod

•

Insert a feeler gauge of the correct thickness be-
tween the adjusting screw/brake lever and the 
stop (arrow).

Feeler gauge thickness:........ 0.2 mm (0.00787 in)

•

Release locknut (1).

•

Insert piston rod (2), turning to right until clear-
ance is present.

•

Turn the piston rod carefully to the left to with-
draw it again until no clearance is present; lock it 
in this position.

•

Tighten locknut/check clearance again.

2

3

4

1

RS

RS340190

GS

1

2

GS340200

34.26

Removing and installing brake pedal

•

Release pin on brake linkage.

•

Remove brake pedal retaining pin (1).

•

Remove brake pedal with spiral spring.

•

Install in the reverse order of work.

•

Lubricate pivot bushing with Shell Retinax A.

e

 Caution:

Check/adjust piston rod relief clearance.
See removal and installation of brake master cylin-
der.
The brake light must come on as soon as the rear 
brake begins to take effect.

X

 Tightening torque:

Brake pedal to footrest plate 
(free from grease)........................................... 37 Nm

1

GS

RS340220

34.27

Removing and installing ABS unit

e

 Caution:

Work on the ABS unit is only to be performed by an 
authorized BMW workshop.

1

3

2

4

6

5

RS340010

34.28

Removing the ABS unit

•

Remove fuel tank.

•

Disconnect ABS brake lines (1) at ABS uni

e

 Caution:

If brake fluid escapes, it may damage paint.
Line connections must be protected against dirt 
penetration; if ncessary seal/cover over.

•

Hold the front brake lever against the handlebar 
grip with a rubber band (to close the brake fluid 
feed bore).

e

 Caution:

Switch off ignition, disconnect and insulate the 
ground (earth) strap.

•

Remove cover (2) from ABS control unit, press 
the lock in with a screwdriver and pull the cover 
up.

•

Detach wires (3). 

•

Pull off 2-pin plug (4).

•

Pull off the central plug (5).

•

Remove the ABS unit 6).

Installing the ABS unit

•

Install the ABS unit (6).

•

Connect the central plug (5).

e

 Caution:

Make sure the cable is not at an angle, or its insula-
tion may be damaged.

•

Reconnect the 2-pin plug in the correct position, 
pushing the two halves fully together, and press 
the two wires into the center (smaller) cable en-
tries.

•

Push the two plugs for the connecting cable/
wiring harness onto the threaded pins with the 
crimp at the front.

•

Press the two cables into the remaining free 
cable entries. 

•

Tighten the nuts.

e

 Caution:

Always use new self-locking nuts.

X

 Tightening torque:

Battery —/M5 ............................................... 3.5 Nm
Battery +/M4 .................................................. 3 Nm

•

Install a new cover.

e

 Caution:

When sliding the cover on, make sure that all cables 
are correctly located in their cable entries. Discard 
the old cover.

•

Screw ABS brake lines (1) to ABS unit.

•

Fill/bleed the brake system.

•

Install the fuel tank.

X

 Tightening torque:

ABS unit to holder
M6 screw ......................................................  9 Nm
M6 screw (Torx) ............................................. 5 Nm
Brake line to ABS unit .................................. 15 Nm
Bleed screw at ABS unit ................................ 9 Nm

34.29

Removing and installing ABS relay 
and relay base

Removing ABS relay

e

 Caution:

Switch off ignition, disconnect and insulate the 
ground (earth) strap.

•

Remove cover (1) from ABS control unit, press in 
the lock with a screwdriver and pull the cover up.

•

Discard the old cover (1).

•

Detach lines (2) and discard nuts.

e

 Caution:

Make sure the cable is not at an angle or its insula-
tion may be damaged.

•

Pull off 2-pin plug (3).

•

Take out relay base (4).

•

Slacken off screws on relay base by app. 2 turns 
with Torx T20.

•

Pull the relay off upwards.

Installing the ABS relay

•

Insert the ABS relay with the FAG inscription 
facing the detent hook.

•

Tighten the screws at the relay base.

•

Push the relay base into the relay housing, at the 
same time pressing both engine cables into the 
left cable entries on the relay housing (red at bot-
tom, black at top).

•

Attach black engine cable to left threaded pin 
(M5) with crimp at back.

e

 Caution:

Make sure the cable is not at an angle, or its insula-
tion may be damaged.

•

Attach 2-pin plug in correct position, pushing it 
on fully and press the two wires into the center 
(smaller) cable entries.

•

Push the two plugs for the connecting cable/
wiring harness onto the threaded pins with 
the crimp at the front..

•

Press the two cables into the remaining free 
cable entries. 

•

Tighten the nuts.

e

 Caution:

Always use new selflocking nuts.

•

Install a new cover (1).

e

 Caution:

When sliding the cover on, make sure that all cables 
are correctly located in their cable entries. Scrap 
the old cover.

3

4

1

2

RS340200

34.30

Removing ABS relay base

e

 Caution:

Switch off ignition, disconnect and insulate the 
ground (earth) strap.

•

Remove cover (1) from ABS control unit, press in 
the lock with a screwdriver and pull the cover out 
upwards.

•

Scrap the old cover (1).

•

Detach the wires (2); scrap the nuts. 

e

 Caution:

Make sure the cable is not at an angle, or its insula-
tion may be damaged.

•

Pull off the 2-pin plug (3).

•

Take out relay base (4).

•

Remove screws at relay base with Torx T20.

•

Remove the ABS relay.

•

Press the contact interlock out of the relay base.

•

Working from the relay side, release the plug with 
special tool Art. No. 50000-017-507 from the 
Grote und Hartmann company. 

e

 Caution:

The contact has a double detent.
When pulling the plug out of the relay base, avoid 
applying too much tension to the cable.
If the cable breaks, the complete 
ABS unit will have to be exchanged.

Installing the ABS relay base

•

Bend up the contact interlock on the plug.

•

Insert the contact into the relay base.

e

 Caution:

The contact must be heard to engage and must be 
firmly located.

•

Insert the ABS relay with the FAG inscription fac-
ing the detent hook.

•

Insert a Torx screw into the ring shoe of the red 
engine cable.

L

 Note:

The crimp side is towards the screw head.