R1100R Major Service Procedure
Major Service - every 24,000 miles
Version: 3/6/00


Mileage:	___________

Date:		___________

Items needed:

oil, 4 qts
oil filter
oil drain plug washer
fuel filter
o-ring for fuel tank cover plate (holds the filter and pump)
gearbox/final drive oil, 1 liter SAE 80W90
plugs
brake fluid

* warm bike up

* drain engine oil

* remove oil filter

* drain gearbox oil

* drain final drive oil

* after engine oil has drained install new filter

* fill engine with 4 qts oil:	____________

* fill gearbox with 800 cc of 80W90 SAE oil ____________

* fill final drive with 230 cc of 80W90 SAE oil ____________

* allow engine to cool overnight

* remove plugs

* adjust valves:

intake = 0.006"
exhaust=0.012"
adjuster screw locknut - 6 ft lb = 72 in lb
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
valve cover bolts - 6 ft lb

*  change plugs gap: 0.031"

left:	__________

right:	__________

torque to 15 ft lb

* check intake manifold clamps (18 inch lb) / check for leaks

* replace air filter

* replace fuel filter

* set clutch freeplay to 5mm at lever tang

* check all brake pads for wear

* replace front brake fluid

* replace rear brake fluid

* check brake system p 1.17

* check battery

* check wheel bearings

* check f & r suspension and steering damper per Haynes p 1.10

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


* lube stands, pivots, cables per Haynes p 1.11

* 4 foot pegs

* clutch cable, throttle cable

* clutch lever pivot

* brake lever pivot

* clutch cable nipples at both ends

* throttle cable

* brake pedal pivot

* shift lever pivots

* speedo cable

* check throttle and choke cables (p 1.13)

* balance throttle bodies

* check gearbox oil

* check final drive oil

* tighten the following nuts


* engine oil drain plug - 24 ft lb

* gearbox oil drain plug - 22 ft lb

* gearbox fill plug - 17 ft lb

* final drive fill plug - 17 ft lb

* final drive drain plug - 17 ft lb

* gear shift lever pivot bolt - 26 ft lb

* front brake lever pivot bolt - 6 ft lb

* rear brake pedal pivot bolt - 28 ft lb

* footrest bolts - 6mm=4 nm/8 mm= 16 ft lb/10 mm=32 ft lb

* center stand bolts - 16 ft lb

* side stand bolts - 32 ft lb

* engine mounting bolts - see p 2.6

* front shock absorber lower mounting bolt - 32 ft lb

* front shock absorber upper mounting bolt - 35 ft lb

* telever/swingarm pivot shaft bolt - 55 ft lb

* handlebar clamp bolts - 16 ft lb

* front axle bolt - 22 ft lb

* front axle clamp bolts - 16 ft lb

* front fork yoke bolts - 

* rear wheel bolts - 88 ft lb final setting

* brake caliper mounting bolts - 30 ft lb

* brake hose banjo bolts - 12 ft lb

* caliper bleed valves - 5 ft lb

* brake disk bolts - 16 ft lb

* muffler front mounting bolts - 15 ft lb

* muffler rear mounting bolts - 18 ft lb

* muffler clamp bolt - 27 ft lb 


Notes: 





































4
please send revisions to mb@rentk.com