BMW R850, R1100, R1150 Repair Manual 1993-2006

The BMW R850, R1100, and R1150 4-valve twin-cylinder motorcycle DIY repair manual by Haynes, covers the following models:

• BMW R850R, 1996-2006
• BMW R850R Comfort, 2004-2006
• BMW R850GS, 1999-2001
• BMW R1100GS, 1994-2000
• BMW R1150GS, 2000-2003
• BMW R1150GS Adventure, 2002-2006
• BMW R1100R, 1995-2001
• BMW R1150R, 2001-2006
• BMW R1150R Rockster, 2003-2005
• BMW R1100RS, 1993-2002
• BMW R1150RS, 2002-2004
• BMW R1100S, 1999-2005
• BMW R1100SS, 1999-2005
• BMW R1100RT, 1996-2001
• BMW R1150RT, 2001-2005

Note: Manual covers all Special Edition and Anniversary models.

Book Excerpt: 1993-2006 BMW R850, R1100, R1150 4-Valve Twins Repair Manual ENGINE, CLUTCH AND TRANSMISSION

AUXILIARY SHAFT, CAMCHAINS AND TENSIONER / GUIDE BLADES NOTE: to remove the auxiliary shaft the engine must be removed from the frame. REMOVAL

1. Remove the engine (see Section 5) and separate the crankcase halves (Section 23).
2. Remove the two upper tensioner and guide blades with their pivot pin, noting which fits on which side (see illustration). Remove the E-clip securing the lower guide blade in the left-hand crankcase half and slide the blade off the pivot pin (see illustration). Unscrew the pivot bolt securing the lower tensioner blade - the bolt is accessed from the rear of the right-hand crankcase half (see illustration). Do not get the various blades mixed up as they must be installed in their original positions.
3. Remove the auxiliary shaft from the engine and slip the camchains off their sprockets (see illustration).
INSPECTION
4. Except in cases of oil starvation, the cam chains wear very little. If the chains have stretched excessively, which makes it difficult to maintain proper tension, they must be replaced.
5. Check the sprockets for cracks and other damage, replacing the shaft if necessary. Note that if a new shaft is installed, new cam chains must also be installed. If the sprockets are worn, the cam chains are also worn, and also the sprockets on the camshafts. If wear this severe is apparent, the entire engine should be inspected for wear.
6. Check the tensioner and guide blades and their pivots for signs of wear and damage and replace them if necessary.
INSTALLATION
7. Apply clean engine oil to the auxiliary shaft bearing surfaces in the crankcase (see illustration). Slip the cam chains around their sprockets, making sure the chains are properly and fully engaged with the sprocket teeth (see illustration). Lay the auxiliary shaft in the right-hand crankcase half (see illustration 27.3).

ELECTRICAL SYSTEM

HANDLEBAR SWITCH CHECK NOTE: If the starter motor engages of its own accord while pulling in the clutch while riding, or if it engages while the engine is idling with the bike at standstill, it is likely that there is water causing a short circuit in the starter button the handlebar. Remove the switch, then clean and dry it using a water dispersant aerosol such as WD40. An improved starter relay was fitted to 1998-on models.

1. Generally speaking, the switches are reliable and trouble-free. Most troubles, when they do occur, are caused by dirty or corroded contacts, but wear and breakage of internal parts is a possibility that should not be overlooked. If breakage does occur, the entire switch and related wiring harness will have to be replaced with a new one, since individual parts are not available.
2. The switches can be checked for continuity using an ohmmeter or a continuity test light.

WARNING! Always disconnect the battery negative (-ve) lead, which will prevent the possibility of a short circuit, before making the checks.

Subject: 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 BMW R850, R1100, R1150 4-Valve Twins service, maintenance, and repair procedures. | ISBN-10: 1785212826 | ISBN-13: 9781785212826 | Haynes 3466