Home

BMW R 1200 CL Repair manual

1. 56 11 3 Installing right cylinder head 57 Adjustment specification 57 Installing left cylinder head 58 Adjustment specification 58 Installing alternator mount cover 60 Installing magnetic gate belt pulley 60 Timing the ignition 61 Installing alternator 62 Installing engine 63 11 4 11 5 11 Technical data R 850 C R 1200 C Engine general Engine design Four stroke flat twin air cool
2. 31 Removing installing conrod 32 Removing and installing alternator cover with engine installed 33 11 Motor 11 2 Contents Page Removing alternator mount cover 33 Renewing radial shaft seal in alternator mount cover 34 Renewing radial shaft seal for rotary breather 34 Removing auxiliary shaft drive 35 Removing oil pump 36 Removing radial shaft seal on crankshaft with engine installed 37 Dismantling crankcase 38 Removing crankshaft auxiliary shaft and timing chain tensioning and slide rails 40 Removing and installing oil pick up basket
3. 46 Installing timing chain tensioning and slide rails 46 Installing auxiliary shaft timing chains 46 Assembling engine block 47 Installing the crankshaft radial seal 49 Installing clutch housing 50 Installing oil pump 51 Installing auxiliary shaft drive 52 Installing piston 53 Installing cylinder 54 Installing cylinder head 55 Adjusting valve clearances
4. 5 Removing and installing alternator 6 Poly V belt adjusting procedure 6 Dismantling reassembling alternator 7 Checking alternator 7 Checking armature for short to ground earth 7 Removing and installing starter motor 8 Dismantling reassembling starter motor 9 Renewing carbon brushes 9 Checking starter motor 9 Checking starter relay 9 Removing and installing magnetic gate
5. 8 Renewing sealing ring for selector shaft 8 Dismantling gearbox 9 Removing gearbox housing 9 Removing selector drum 10 Dismantling assembling selector shaft 10 Removing gearbox shafts 11 Renewing deep groove ball bearing on intermediate shaft 11 Dismantling assembling input shaft 12 Dismantling input shaft 12 Assembling input shaft 13 Dismantling reassembling output shaft
6. 23 Installing selector drum 23 Assembling gearbox housing 24 23 Gearbox 23 2 23 3 23 Technical data R 850 C R 1200 C Type of gearbox 5 speed gearbox with claw action shift and inte gral reaction damper for all gears Gear shift type Pedal operated lever and selector drum with overshoot detent Gear ratios 1st gear 3 864 2nd gear 3 022 3rd gear 2 393 4th gear 1 962 5th gear 1 511 Oil grade all the year round Brand name SAE 90 hypoid gear oil API Class GL 5 Filling capacity Initial filling l Imp pint US quart 1 0 1 76 1 06 up to the lower edge of the filler hole During oil changes l Imp pint US quart approx 0 8 0 2 1 41 0 35 0 85 0 21 up to the lower edge of the filler hole Endplay of spring segment at input shaft mm in 0 4 0 6 0 0157 0 0236 Endplay at 1st gear output shaft mm in 0 1 0 33 0 0039 0 0130 Endplay at 2nd gear output shaft mm in 0 1 0 33 0 0039 0 0130 Endplay 3rd 4th gear total play output shaft mm in 0 1 0 67 0 0039 0 0264 Selector shaft endplay mm in 0 1 0 3 0 0039 0 0118 Length of intermediate shaft fully compressed mm in
7. 26 Removing valve stem seals 26 Checking valves for wear 27 Remachining valve seat 27 Checking and repairing cylinder head 27 Checking valve guide for wear 27 Replacing valve guides 28 Installing valve and valve stem seal 29 Removing cylinder barrel 30 Removing dismantling piston 30 Checking pistons and cylinders 31 Assembling pistons
8. 10 Timing the ignition 11 12 Engine electrics 12 2 12 3 12 Technical data R 850 C R 1200 C Starter motor Type Permanent magnet motor with planetary gear drive Gear ratios Planetary gears 5 5 1 Power rating kW 1 1 Alternator Type Three phase alternating current generator with integrated all electronic voltage regulator Drive Poly V belt Gear ratios 1 1 5 Maximum output rating W V 700 14 Maximum current at engine speed 4000 min 1 A 50 Nominal current at engine speed 1000 min 1 A 18 Max operating speed min 1 20 000 Spark plug Bosch FR 6 DDC Electrode gap mm in 0 8 0 03 Wear limit mm in 1 0 0 04 Thread metric M 14 x 1 25 Ignition Ignition system Motronic mapped characteristic control Ignition trigger Two magnetic gates Hall effect transmitters driven from crankshaft Ignition timing CS 0 43 before OT Static ignition timing CS Adjustment at TDC Ignition coil Twin spark coil Resistance Primary 0 5 between terminals 15 and 1 Secondary k 7 5 between terminals 4a and 4b 12 4 12 5 Removing and installing coil and ignition lead Remove fuel tank e Caution Switch off ignition Disconnect ground earth cable at battery and insulate
9. 41 Replacing oil level sight glass 41 Removing conrods 41 Checking conrods 41 Measuring main and big end bearing play 42 Measuring radial bearing play 42 Installing main bearing 43 Measuring axial bearing play 43 Measuring big end bearing play 44 Assembling engine 45 Installing conrod 45 Installing crankshaft
10. 18 Front brake 00 Maintenance and general instructions 00 2 Contents Page Rear brake Checking brake pads and discs for wear renewing 19 Inspections II and III Checking front brake pad wear 19 Checking rear brake pad wear 19 Checking brake disc wear 19 Renewing brake pads Front brake 20 Renewing brake padsRear brake 20 Renewing brake fluid and bleeding brake system 21 Renew the brake fluid annually Inspection IV ABS Inspection II and III Bleeding front brake circuit renewing brake fluid 21 Additionally with ABS Bleeding rear brake circuit renewing brake fluid 23 Additionally with ABS Checking clutch operating fluid level
11. 0 30 mm 0 012 in X Tightening torque Locknut 8 Nm After adjusting check valve operating clearanc es again it should be possible to pull the correct feeler gauge through between the valve stem and the adjusting screw with only slight resist ance Assemble in reverse order e Caution Make sure that gasket is correctly seated Gaskets and sealing faces must be free from oil or grease X Tightening torque Cylinder head cover 8 Nm C000210l C000070 TDC RS110980 00 27 Checking renewing spark plugs Inspection II renewing Inspection III Unscrew and remove spark plugs with the spark plug wrench BMW No 12 3 510 e Caution Do not bend electrodes risk of breakage Electrode gap 0 8 mm 0 031 in Gap wear limit 1 0 mm 0 039 in X Tightening torque Spark plug 20 Nm Check synchronising Inspections I II and III The engine must be at regular operating temper ature Connect the BMW Synchrotester hose to the vacuum stub pipe arrow and the lines to the MoDiTeC L Note If the left right readings differ by more than 30 milli bars 0 42 psi check the air intake system for leaks C000060 12 3 510 C000220 00 28 Final inspection with
12. 6 Removing and installing throttle potentiometer 6 Removing and installing injectors 6 Removing and installing Motronic control unit 7 13 Fuel preparation and control 13 2 13 3 13 Technical data R 850 C R 1200 C Fuel grade Super premium unleaded 95 octane RON Mixture preparation Motronic MA 2 4 Throttle stub pipe intl dia mm in 35 1 38 Throttle angle in rest position depending on throttle positioner Air cleaner Flat pattern paper element 13 4 13 5 Removing and installing air cleaner a See Group 46 Removing installing rear frame Removing and installing throttle stub pipe Remove throttle stub pipe 1 Removing and installing throttle potentiometer Remove throttle potentiometer 2 Adjusting throttle potentiometer with BMW MoDiTeC after installing Mark screws with a paint spot C130010 2 3 1 13 6 Removing and installing throttle positioner Remove the throttle positioner 3 e Caution The throttle positioner operates at the control unit voltage of 5 V It must not be connected directly to the motorcycle s electrical system X Tightening torque Throttle positioner retaining screw clean thread Loctite
13. 10 Nm C000020 00 17 Renewing Poly V belt every 60 000 km 36 000 miles Inspection III Remove the cover Use the spark plug cap assembly tool from the toolkit to pull off the spark plug caps Use spark plug wrench BMW No 12 3 510 to unscrew and remove the spark plugs Remove the horn with its mount Remove front cover Remove vent line 1 Slacken off alternator mounting screws 1 3 4 and install a new Poly V belt if necessary Poly V belt adjusting procedure Poly V belt installation procedure Place the Poly V belt in position tension it and turn the engine over once then release belt ten sion Poly V belt tensioning procedure 1 Screw hex nut 1 on adjusting screw 2 up handtight no tools to be used 2 Tighten adjusting screw 2 with a torque wrench and keep it under tension 3 Tighten upper retaining nut 3 then release the tension at the adjusting screw 4 Tighten all screws and nuts X Tightening torque Poly V belt preload 8 Nm Alternator to alternator support cover 20 Nm Vent line at generator mount cover Banjo screw 25 Nm Machine screw 10 Nm e Caution Install the vent line with new O ring seals C000060 12 3 510 C000070 1 TDC RS110480 1 2 3 4 00 18 Checking brake
14. 14 Stripping down output shaft 14 Assembling output shaft 15 Checking endplay 16 Checking adjusting fully compressed length of gearbox shafts selector drum 17 Checking adjusting fully compressed length of intermediate shaft 17 Checking adjusting fully compressed length of output shaft 18 Checking adjusting fully compressed length of input shaft 19 Checking adjusting fully compressed length of selector drum 20 Shimming selector shaft 21 Assembling gearbox 22 Installing input output and intermediate shaft 22 Installing selector shaft
15. 90 2 M 10 bolt 40 Nm 3 M 6 screw 9 Nm X Tightening torque Take up slack after 1000 km app 600 miles Tighten cylinder head nuts in a crosswise pattern 1 Unfasten one nut 2 Tighten one nut to initial value 20 Nm 3 Tighten nut to wrench angle 180 4 Unfasten retighten M10 screw 40 Nm Fit camshaft chain sprocket in accordance with adjustment specification Lock clutch housing with special tool BMW No 11 5 640 Tighten camshaft chain sprocket X Tightening torque Camshaft sprocket retaining screw 65 Nm Insert the left side camshaft sprocket with pin into the camshaft and set the left cylinder to TDC on the ignition stroke Fit camshaft chain sprocket in accordance with adjustment specification Tighten camshaft chain sprocket Install chain tensioner Check that marks on camshaft sprockets are in accordance with adjustment specification X Tightening torque Chain tensioner 32 Nm RS110930 M6 x 30 M6 x 30 M6 x 30 M6 x 60 2 1 11 56 Adjusting valve clearances Set piston to TDC on the ignition stroke Measure valve clearance with feeler gauge Correct valve clearance with adjusting screw and lock into position Valve clearances with engin
16. Install alternator Poly V belt adjusting procedure Poly V belt installation procedure Screw hex nut 1 on adjusting screw 2 up handtight no tools to be used Tighten adjusting screw 2 with a torque wrench fully tighten retaining nut 3 slacken adjusting screw and tighten screws fully X Tightening torque Pre tension Poly V belt with adjusting screw 8 Nm Alternator to alternator support cover 20 Nm Install front cover RS110480 2 3 1 RS110490 11 63 Install oil filter with oil filter wrench BMW No 11 4 650 Insert and tighten oil drain plug with a new seal X Tightening torque Oil filter sealing face lightly oiled 11 Nm Oil drain plug 32 Nm Install spark plugs with spark plug socket wrench BMW No 12 3 510 X Tightening torque Spark plug 20 Nm Installing engine Work in reverse order to that stated for removal 11 4 650 RS110950 12 3 510 RS000010 11 64 12 1 Contents Page 12 Technical data 3 Removing and installing coil and ignition lead 5 Check ignition coil resistance
17. Telltale and warning lights Clutch gear shift Front and rear brakes steering Instruments If necessary test ride Charged as an additional item BMW AG Motorcycle Division Maintenance schedule R 1100 S R 850 1200 C R 1150 GS Order No 01 71 0 008 872 UX VS 2 06 99 Printed in Germany Customer Licence plate No Order No Mechanic s signature BMW Pre delivery check Check the shipping crate for damage Motorcycle unpack install remaining items inspect for damage check that delivery is complete tools documentation keys correct optional extras Fill and charge the battery mark with charging date Check engine oil level when cold add oil if necessary Check clutch operating fluid level and brake fluid levels at front and rear Check headlight beam angle adjust if necessary Check security of rear wheel studs comply with correct tightening torque Check tyre pressures Fill fuel tank Final inspection as functional check Clutch gear shift Front and rear brakes Lights and signalling equipment telltale and warning lights instruments Check operation of optional extras ABS If necessary test ride Confirm pre delivery check in Service and Technical Booklet Final cleaning Motorcycle handed over on BMW AG Motorcycle Division Pre delivery check R 1100 S R 850 1200 C R 1150 GS 00 Maintenance and general instruc
18. 13 Removing engine 15 Dismantling engine 18 Removing cylinder head cover 19 Locking the engine in the TDC position 20 Top dead centre on ignition stroke 20 Removing and installing chain tensioner 21 Assembly specification for timing chain tensioner 21 Removing valve gear holder 22 Dismantling reassembling valve gear holder 23 Removing cylinder head 25 Dismantling checking repairing and re assembling cylinder head 26 Removing and installing valves
19. Oil cooler to frame 9 Oil cooler return line to engine block 35 Screw in union for oil cooler connection at engine block 35 clean threads and apply Loctite 603 to inner and outer threads and in the contact face area Cylinders Tightening sequence 1 M 8 screw 20 2 M 6 screw 9 3 Chain guide rail pivot screw 18 Timing chain Chain tensioner 32 Connecting rod Big end cap Joint torque 20 Additional wrench angle 80 Crankcase Tightening sequence 1 M10 screw oiled 45 2 M 8 screw oiled 20 3 M 6 screw 9 Model R 850 1200 C Connection Nm 00 5 12 Engine electrics Starter motor to engine 20 Starter cover to housing 7 Positive lead to starter motor 10 Alternator to cover mount 20 Tensioning and retaining strap at alternator 20 Spacer at alternator 20 Positive lead to alternator 15 Belt pulley at alternator 50 Belt pulley to crankshaft 50 Poly V belt preload 8 Spark plug 20 Ignition coil holder to frame 9 13 Fuel preparation and control Oil temperature sensor to engine block 25 Air temperature sensor to air cleaner cover 10 16 Fuel tank and lines Fuel tank to rear frame 10 18 Exhaust system Manifold to cylinder head 24 Clip on muffler 55 apply Never Seez to clip contact surface Oxygen sensor lambda probe to muffler 45 apply Never Seez to thread 21 Clutch Clutch housing Joint torque 40 oil screw threa
20. Permissible oil consumption l 1000 km miles per Imp pint miles per US quart 1 0 350 590 Oil pump Oil pump 2 Duocentric pumps Housing depth mm in mm in 12 02 12 05 0 473 0 474 10 02 10 05 0 394 0 396 Height of rotor mm in mm in 11 95 11 98 0 470 0 472 9 95 9 98 0 392 0 393 Axial play mm in 0 04 0 1 0 002 0 004 Wear limit mm in 0 25 0 010 11 6 Technical data R 850 C R 1200 C Valves Included angle between valves 41 Valve clearances with engine cold max 35 C 95 F 0 15 0 006 0 30 0 012 Inlet valve mm in Exhaust valve mm in Valve timing At zero valve clearance and 3 mm 0 12 in valve lift Inlet opens 17 after TDC Inlet closes 15 after BDC Exhaust opens 15 before BDC Exhaust closes 17 before TDC Tolerance 3 Valve head dia Inlet mm in 32 1 26 34 1 34 Exhaust mm in 27 1 06 29 1 14 Stem dia Inlet mm in 4 966 4 980 0 1955 0 1960 Wear limit mm in 4 946 0 1947 Exhaust mm in 4 956 4 970 0 1951 0 1956 Wear limit mm in 4 936 0 1943 Valve head edge thickness Inlet mm in 1 00 0 2 0 04 0 008 Wear limit mm in 0 5 0 02 Exhaust mm in 1 00 0 2 0 04 0 008 Wear limit mm in 0 5 0 02 Max runout of valve head at valve seat Inlet exhaust mm in 0 035 0 0014 Valve seat ring Valve seat angle Inlet 45 Exh
21. 24 Inspections I II and III Checking tightness of rear wheel studs 25 Inspection I Checking rear wheel bearing play by tilting wheel 25 Inspection III Checking swinging arm bearings adjusting if necessary 25 Inspections I and III Greasing the side prop stand pivot 25 Inspections I II and III Checking function of side prop stand contact switch 25 Inspections I II III and IV Tightening cylinder heads 26 Inspection I Checking adjusting valve operating clearances 26 Inspections I II and III Checking renewing spark plugs 27 Inspection II renewing Inspection III Check synchronising 27 Inspections I II and III Final inspection with road safety and functional check 28 Inspections I II III and IV Road safety check Roadworthiness check 00 3
22. Remove the starter motor Remove rear leading link mount Removing alternator mount cover Detach the alternator Remove rotary breather line 1 Lock the clutch housing with special tool BMW No 11 5 640 Remove pulley 2 Remove magnetic gate 3 L Note If complete alternator mount cover is removed leave magnetic gate 3 installed Remove alternator mount cover 4 11 5 640 RS110230 4 3 1 2 11 34 Renewing radial shaft seal in alternator mount cover Carefully lever radial shaft seal out using a screwdriver Drive in the new radial shaft seal with drift and sliding sleeve BMW No 11 5 680 L Note Slide new radial shaft seal over taper on sliding sleeve pre shape and pull off Renewing radial shaft seal for rotary breather Carefully lever radial shaft seal out using a screwdriver Carefully pre form the lip of the radial shaft seal by hand Oil the new radial shaft seal lightly and drive it in with handle BMW No 00 5 550 and drift BMW No 11 5 650 11 5 680 RS110240 00 5 550 RS110241 11 5 650 11 35 Removing auxiliary shaft drive Align markings arrows on timing pinion and chain sprocket Unscrew and remove cooling oil pipe 1 swing the pipe forwards Remove chain tensioner 2 Remove chain tensioning rail 3 Remove chain guide rail 4 Lock clutch housing with special tool BMW No 11 5
23. 3rd groove equal chamfer ring 2nd groove micro chamfer ring 1st groove asymmetric convex oval section a See Technical data e Caution The tubular spring ring gap must be at 180 to the equal chamfer ring gap Install with Top uppermost RS110180 100 20 RS110970 A RS110200 RS110190 1 R 850 1 2 3 11 32 Removing installing conrod Turn crankshaft to TDC position Lock the clutch housing with special tool BMW No 11 5 640 Remove conrod L Note Conrods can also be removed installed with the crankshaft removed e Caution Do not accidentally interchange conrods or bearing shells Install conrods Installed direction of conrods lettering facing up e Caution Oil the bearings Screw the big end bolts in by hand then tighten them with a tightening angle indicator BMW No 11 2 500 e Caution Use big end bolts once only X Tightening torque Big end bolts oiled Joint torque 20 Nm Wrench angle 80 11 5 640 RS110210 TDC 11 2 500 11 33 Removing and installing alternator cover with engine installed e Caution Disconnect earth ground lead from battery Insulate earth ground lead Detach the horn Remove the oil cooler line Separate the Hall effect signal transmitter plug
24. BMW No 11 2 210 tighten the big end bolt X Tightening torque Big end bolts oiled Joint torque 20 Nm Wrench angle 80 Measure big end bearing with internal gauge in thrust direction Enter measured values on record sheet and de termine big end bearing clearances a See Technical data RS110340 11 2 210 RS110350 RS110360 11 45 Assembling engine Installing conrod Clamp crankshaft in a vise provided with protec tive jaws Oil the big end bolts screw them in by hand and tighten with angle gauge BMW No 11 2 210 e Caution Oil the bearings Do not accidentally confuse conrods or bearing shells Always use new big end bolts Installed direction of conrods lettering facing up X Tightening torque Big end bolts oiled Joint torque 20 Nm Wrench angle 80 11 2 210 RS110370 11 46 Installing crankshaft e Caution Oil the bearings Installing timing chain tensioning and slide rails Seal pivot pin for tensioning rail slide rail at clutch side arrow with 3 Bond 1209 Insert pivot screw 1 into chain tensioner rail using a new seal X Tightening torque Chain guide rail pivot pin 18 Nm Installing
25. 198 95 199 00 7 833 7 835 Length of output shaft fully compressed mm in 192 95 193 00 7 597 7 599 Length of input shaft fully compressed mm in 138 55 138 60 5 455 5 457 Length of selector drum fully compressed mm in 111 80 111 90 4 402 4 406 23 4 23 5 Removing and installing gear pedal X Tightening torque Gear pedal to frame 41 Nm Removing gearbox e Caution Switch off ignition Disconnect earth ground lead from battery Insulate earth ground lead Attach stand BMW No 00 1 520 to motorcycle Remove seat Remove side trim Remove fuel tank Remove rear wheel Detach rear brake caliper Detach ABS sensor Detach speedometer signal sensor Detach wire protection at swinging arm Tie up swinging arm with a suitable strap Remove suspension strut L Note Press to rear at top Pull swinging arm upwards with strap Removing exhaust manifold Remove silencer muffler Detach plug at oxygen sensor Remove rear wheel drive unit Detach brake hose holder Press off left swinging arm bearing cap e Caution When installing again make sure that the O ring is in good condition The opening must face down so that water can drain out Loosen the left swinging arm Take out the screws at the right swinging arm bearing Using pull rod BMW No 00 8 581 an
26. 2701 Removing and installing throttle potentiometer When a new throttle potentiometer is installed it must be adjusted in accordance with the BMW MoDiTeC reading Mark the retaining screws arrows with a paint spot Removing and installing injectors Press in the spring catch at the injector plug 1 and pull off the plug Unfasten retainer 2 for fuel pipe and pull off the pipe Remove injector Install by following the above work instructions in the reverse order e Caution The keeper 2 must be inserted from the inside out wards It then prevents the injector from turning Make sure that the keeper 2 engages correctly Make sure that O rings at the injector are in good condition KR130160 C130020 2 1 13 7 Removing and installing Motronic control unit Remove fuel tank e Caution Switch off ignition disconnect earth ground lead at battery and insulate it Remove Motronic control unit Remove connector strip Install by following the above work instructions in the reverse order C130030 13 8 16 1 Contents Page 16 Technical data 3 Removing and installing fuel tank 5 Removing and installing fuel filter fuel pump and fuel level
27. 640 Unscrew and remove chain sprocket retaining bolt 5 Remove rotor 6 with chain sprocket 7 and tim ing chain 8 If necessary remove chain sprocket 9 11 5 640 RS110251 1 8 2 4 9 6 7 5 3 RS110961 11 36 Removing oil pump Remove oil pump cover 1 Remove complete oil pump 2 together with cooling oil pipe 3 and dismantle e Caution Check installed positions of parts which have al ready been run together RS110410 M6 x 45 M6 x 50 M6 x 45 M6 x 45 M6 x 50 3 1 2 11 37 Removing radial shaft seal on crankshaft with engine installed Lock clutch housing with special tool BMW No 11 5 640 Remove the clutch Carefully lever radial shaft seal out using a screwdriver e Caution Avoid damaging the sealing faces on the housing and the crankshaft L Note When the crankcase is dismantled the radial shaft seal can be taken out C210010 11 5 640 RS110270 11 38 Dismantling crankcase Turn engine on to its side Remove screws on right side RS110261 M10 x 100 M10 x 100 M8 x 80 M8 x 80 M8 x 35 M8 x 35 11 39 Turn engine on to its side Remove screws on left side Remove upper section of crankcase RS110260 M6 x 50 M6 x 50 M6 x 50 M6 x 50 M6 x 25 M6 x 25 M10 x 100 M10 x 100 M6 x 50 M6 x 50 M6 x 50 M6 x 35 M6 x 35 M6 x
28. Carefully dismantle magnetic trigger lead Tension Poly V belt according to installation procedure X Tightening torque Pre tension of Poly V belt 8 Nm Alternator to alternator mount cover 20 Nm Belt pulley to crankshaft 50 Nm RS120090 3 2 4 6 5 7 1 12 11 Timing the ignition Screw dial gauge holder BMW No 00 2 650 and dial gauge BMW No 00 2 510 into right or left spark plug hole Turn the engine over until the piston is at TDC Set the dial gauge pointer to zero Check the dial gauge reading Turn the engine over until the piston is at TDC The dial gauge pointer must be at zero Connect BMW MoDiTeC with adapter lead to the Hall effect gate plate Adjust as stated in the tester guide 00 2 650 C120040 12 12 13 1 Contents Page 13 Technical data 3 Removing and installing air cleaner 5 Removing and installing throttle stub pipe 5 Removing and installing throttle potentiometer 5 Removing and installing throttle positioner
29. Caution Note direction of fuel flow at filter Secure non reusable hose clips with pliers BMW No 13 1 500 C160020 5 1 3 2 4 16 7 Removing and installing fuel pump and fuel level sensor Detach the electrical connections at the fuel pump 4 Release the hose clip at the fuel pump Remove fuel pump Install by following the above work instructions in the reverse order Secure non reusable hose clips with pliers BMW No 13 1 500 e Caution Use only an O ring 5 in good condition After installing check fuel pump assembly for leaks X Tightening torque Fuel pump assembly to tank 6 Nm Checking fuel pump pressure Connect test pressure gauge BMW No 16 1 500 at the pressure side Run engine at idle speed Fuel pressure Desired value 3 0 2 bar 42 69 2 85 psi L Note If fuel pressure is low check pump fuel filter pres sure regulator and fuel line Removing and installing fuel distributor and pressure regulator Remove fuel tank Remove the battery ABS Remove the ABS unit Remove the battery carrier Remove the fuel distributor with pressure regula tor 1 from the holder Install by following the above work instructions in the reverse order ABS Bleed the brake system 16 1 500 C160030 C130011 1 16 8 18 1 Contents Page 18 Removing and installing ex
30. Checking rear brake pad wear It should not be possible to see the brake disc through the hole arrow in the inner brake pad If the brake disc is visible the wear limit has been reached and the pads must be renewed Checking brake disc wear Examine the brake discs carefully for cracks damage distortion wear and score marks Brake disc wear limit front 4 5 mm 0 177 in rear 4 6 mm 0 181 in C000100 C000110 C000120 C000130 00 20 Renewing brake pads Front brake Detach remove brake caliper from mounting ar row Remove the split pin keeper 1 from the retain ing pin 2 Drive out retaining pin 2 Remove brake pads by pulling downwards Install by following the above work instructions in the reverse order Before installing the brake caliper force the pis tons fully back with resetting tool BMW No 34 1 500 X Tightening torque Brake caliper at fork slider tube 40 Nm Renewing brake pads Rear brake Loosen the rear wheel Unfasten remove brake caliper Remove circlip arrow at retaining pin Drive the retaining pin out towards the wheel side Remove brake pads Install by following the above work instructions in the reverse order Before installing the brake caliper depress the piston fully X Tightening torque Brake caliper
31. and cover Install clutch housing with mark 1 aligned with crankshaft mark 2 Lock the clutch housing with special tool BMW No 11 5 640 Insert all screws by hand and tighten down X Tightening torque Clutch housing to crankshaft screw threads oiled 40 Nm Additional wrench angle 32 C210010 11 5 640 2 1 11 51 Installing oil pump e Caution Oil the sliding contact faces Install outer rotor 1 of oil pump in pump hous ing Install oil pump housing with cooling oil pipe 2 e Caution O ring 3 must be in good condition Install Woodruff key 4 outer rotor 5 and inner rotor 6 in cooling oil pump Screw housing cover 7 on to oil pump e Caution Note different lengths of screw X Tightening torque M 6 screw 9 Nm Pressure relief valve 35 Nm Oil pressure switch 30 Nm RS110411 4 5 6 7 5 1 3 2 M6 x 50 M6 x 45 M6 x 45 M6 x 50 M6 x 45 11 52 Installing auxiliary shaft drive Set crankshaft mark against mark on auxiliary shaft e Caution Adjust according to the adjusting instructions a See Installing cylinder head Lock the clutch housing with special tool BMW No 11 5 640 Install chain sprocket
32. it Pull off spark plug cap with special puller BMW No 12 3 520 Release threaded connection for central electri cal equipment box Remove ignition leads Check ignition coil resistance Test with BMW MoDiTeC 12 3 520 C120030 12 6 Removing and installing alternator Remove seat Remove fuel tank e Caution Switch off ignition Disconnect ground earth cable at battery and insulate it Remove horn with holder Remove front cover from engine Remove alternator retainers 1 2 3 Remove rotary breather tube Remove Poly V belt Remove the starter motor Lock clutch housing with special tool BMW No 11 5 640 Remove Poly V belt pulley with rotor gate at crankshaft Remove the left exhaust pipe Drain engine oil Remove the oil cooler return line Pull the rear of the motorcycle down to the hoist platform and secure it with a strap or similar Detach the left air intake flange e Caution Mask off the leading link to prevent it from being scratched Release the threaded connection for the lower suspension strut mount Release the leading link shaft at the right and re move it to the left Pull the leading link forwards Place sliding sleeve BMW No 11 5 680 on the crankshaft and remove the alternator support cover Detach the central electrical equipment box and raise it as far as possible Detach the conn
33. on the silencer muffler X Tightening torque Exhaust manifold to cylinder head 24 Nm Clip at silencer muffler coat clip contact face with Never Seez 55 Nm C180010 11 7 020 1 18 4 21 1 Contents Page 21 Technical data 3 Removing and installing clutch 5 Removing clutch 5 Installing clutch 5 Removing and installing clutch hydraulic line 6 Removing and installing clutch slave cylinder 6 Filling bleeding clutch line 7 21 Clutch 21 2 21 3 21 Technical data R 850 C R 1200 C Type of clutch single dry plate with increased leverage dia phragm spring Operation hydraulic with master and slave cylinders Master cylinder piston mm in 13 0 51 Slave cylinder piston mm in 24 0 94
34. road safety and functional check Inspections I II III and IV Road safety check Check wheels and tyres Check correct tyre pressures Wait at least 10 minutes after the trial run road test before checking correcting engine oil level Tyre pressures Solo front 2 2 bar 31 3 psi rear 2 5 bar 35 6 psi With pillion passenger front 2 5 bar 35 6 psi rear 2 7 bar 38 4 psi With pillion passenger luggage front 2 5 bar 35 6 psi rear 2 9 bar 41 2 psi Roadworthiness check Lights Telltale warning lights Horn Instruments Special equipment Clutch Gear shift Steering Foot brake and handbrake Trial run if necessary 11 1 Contents Page 11 Technical data 5 Sectioned drawing of engine 11 Lubricating oil circuit 12 Coolant circuit
35. sensor 6 Removing and installing fuel filter 6 Removing and installing fuel pump and fuel level sensor 7 Checking fuel pump pressure 7 Removing and installing fuel distributor and pressure regulator 7 16 Fuel tank and lines 16 2 16 3 16 Technical data R 850 C R 1200 C Fuel tank Tank capacity l Imp gal US gal 17 3 74 4 50 including reserve of l Imp gal US gal 4 0 88 1 06 Fuel pump Type Gear type Make VDO Operating voltage V 12 Fuel pressure bar psi 3 0 2 42 69 2 85 Delivery volume l h Imp gal h US gal h 110 24 21 29 06 16 4 16 5 Removing and installing fuel tank Seal the fuel feed and return lines with a hose clip BMW No 13 3 010 detach and pull off X Tightening torque Fuel tank to rear frame 22 Nm 13 3 010 C160010 16 6 Removing and installing fuel filter fuel pump and fuel level sensor e Caution Fuel is flammable and a hazard to health Observe relevant safety regulations Drain fuel tank Remove fuel pump unit 1 and detach hoses 2 Removing and installing fuel filter Release hose clips at fuel filter 3 e
36. specification for timing chain ten sioner Removal Remove timing chain tensioner then remove camshaft sprocket from camshaft Installing First install camshaft sprocket then timing chain tensioner e Caution Failure to observe this sequence can cause the chain tensioner piston to fall into the left side of the timing chain cavity X Tightening torque Chain tensioner 32 Nm RS110060 11 22 Removing valve gear holder Remove camshaft sprocket cover Unscrew press off camshaft sprocket L Note If the camshaft sprocket 1 is not removed after loosening it must be held firmly and prevented from falling into the engine block e g with a cable strap Remove valve gear holder Secure rockers with a rubber band 2 L Note If no work is carried out on the valve gear holder re move it together with the cylinder head RS110070 M6 x 60 M6 x 30 M6 x 30 M6 x 30 1 2 RS110051 11 23 Dismantling reassembling valve gear holder Remove bearing cap Insert a suitable drift into the bore arrow of the rocker shaft and pull the shaft out of the mount by twisting it in both directions Remove pushrods e Caution Do not accidentally confuse rocker shafts and push rods RS110080 M8 x 40 M8 x 40 M8 x 30 11 24 Remove camshaft bearing cap 1 Remove camshaft and bearings 2 Remove bucket type tapp
37. system for correct operation and freedom from leaks repairing renewing if necessary Inspection III Checking brake system for leaks Checking brake fluid level L Note The brake fluid volume between MIN and MAX is sufficient for the complete range of pad wear from new to the wear limit It is not normally necessary to add fluid to compen sate for pad wear If the level drops below the minimum mark this indi cates some other fault Inspections I II and III Front brake Make sure that the specified setting distance between handlebar and fuel tank 30 50 mm 1 2 2 in is correct Check with the motorcycle on its side prop stand Turn the handlebar fully to the left The brake fluid must not drop below the mini mum level 2 mm 0 08 in below the ring mark ar row Brake fluid grade DOT 4 Rear brake Position the motorcycle horizontally with auxiliary stand BMW No 00 1 550 Brake fluid must not drop below the minimum level arrow Brake fluid grade DOT 4 CUB0110 C000090 00 19 Checking brake pads and discs for wear renewing Inspections II and III Checking front brake pad wear Examine the wear limit marks arrows e Caution Brake pad thickness must not fall below the minimum value Change pads only as a complete set Minimum lining thickness 1 5 mm 0 06 in
38. temperature plug off the air cleaner cover Detach the gear lever at the pivot Remove the gear lever Separate the plug for the throttle angle potenti ometer and the throttle positioner at the left plug retaining plate Disconnect both fuse boxes at the plug retaining plate Separate the side prop stand safety switch plug Separate the neutral indicator plug Detach the left plug retaining plate Remove the injector nozzles Pull the plug off the injector line Separate the plug for the rear brake light switch and detach the wire Detach the vent hose at the air cleaner housing Disconnect the throttle cable at the twistgrip Remove rear section of frame Remove the auxiliary stand Remove the footrest holder Remove the starter motor cover Detach cable from starter motor Remove the starter motor Separate the clutch line where it passes through the frame Remove the clutch slave cylinder with line Pull out the thrust rod Detach the gearbox When removing the gearbox pull it out on guide pins BMW No 23 1 820 Remove the Motronic control unit Disconnect the wires in the central electrical equipment box Instruments Right combined switch Left combined switch Front brake light switch Clutch switch Front ABS sensor Undo the cable straps at the wiring Detach the central electrical equip
39. 0 25 041 0 9851 0 9859 Auxiliary shaft dia front back mm in 24 959 24 980 0 9827 0 9835 Radial clearance mm in 0 040 0 082 0 0016 0 0032 Wear limit mm in 0 17 0 007 Crankshaft Marking of main bearing and crankpin on front crank web no paint mark Grinding stage 0 paint mark Grinding stage 1 0 25 mm 0 010 in Grrinding stage 0 grinding stage 1 0 25 mm 0 010 in Guide bearing bore dia mm in 64 949 64 969 2 5571 2 5579 Guide bearing dia mm in Green 59 964 60 003 2 3609 2 3624 Yellow 59 974 60 013 2 3612 2 3628 Main bearing journal dia mm in Green 59 939 59 948 2 3598 2 3602 Yellow 59 949 59 958 2 3602 2 3606 Radial clearance mm in 0 016 0 064 0 0006 0 0025 Wear limit mm in 0 1 0 004 Main bearing bore dia mm in 60 000 60 019 2 3622 2 3629 Main bearing dia mm in Green 54 998 55 039 2 1653 2 1669 Yellow 55 008 55 049 2 1657 2 1673 Main bearing journal dia mm in Green 54 971 54 980 2 1643 2 1646 Yellow 54 981 54 990 2 1646 2 1650 Radial clearance mm in 0 018 0 068 0 0007 0 0028 Wear limit mm in 0 13 0 0051 Width of guide bearing mm in 24 890 24 940 0 9799 0 9819 Bearing width of main bearing journal mm in 25 020 25 053 0 9851 0 9864 Axial play mm in 0 080 0 163 0 0031 0 0064 Wear limit mm in 0 2 0 008 Grindin
40. 0 mm 3 94 in from the top edge mm in 0 04 0 0016 Pistons Piston dia Measuring plane A see Checking pistons and cylinders A mm in 87 465 87 477 3 4435 3 4440 100 971 100 983 3 9753 3 9758 Wear limit mm in 87 390 3 4405 100 895 3 9723 B mm in 87 477 87 485 3 4440 3 4443 100 983 100 995 3 9753 3 9763 Wear limit mm in 87 400 3 4409 100 905 3 9727 AB mm in 87 473 87 481 3 4438 3 4441 100 979 100 987 3 9756 3 9759 Wear limit mm in 87 395 3 4407 100 900 3 9725 Installed clearance mm in 0 011 0 035 0 0004 0 0013 0 005 0 029 0 0002 0 0011 Total wear clearance of piston and cylinder mm in 0 12 0 005 Piston pin bore dia mm in 22 005 22 011 0 8664 0 8666 Weight classes and Weight difference in one class grammes oz 10 0 353 complete with pins and rings Direction of installation Arrow on piston crown pointing to exhaust side Production locating point towards exhaust side see Installing piston 11 10 Technical data R 850 C R 1200 C Piston rings 1st groove Piston ring asymmetrical convex oval Height mm in 1 170 1 190 0 0461 0 0469 Wear limit mm in 1 1 0 043 Gap clearance mm in 0 1 0 3 0 004 0 012 Wear limit mm in 0 8 0 031 Side clearance mm in 0 030 0 070 0 0012 0 0027 Wear limit mm in 0 15 0 0006 2nd groove Micro taper compres
41. 00 Tightening torques Model R 850 1200 C Connection Nm 11 Engine Cylinder head Tightening sequence 1 Tighten cylinder head nuts oiled crosswise 1 1 Tighten all nuts to correct torque for joint 20 1 2 Tighten all nuts to correct angle 90 1 3 Tighten all nuts to correct angle 90 2 M 10 bolt 40 3 M 6 screw 9 After 1000 km 600 miles tighten cylinder head nuts crosswise 1 Unfasten one nut 2 Tighten one nut to initial value 20 3 Tighten nut to wrench angle 180 4 Unfasten retighten M10 screw 40 Timing gear carrier to cylinder head 9 Bearing cap on rocker shaft 15 Locknut valve adjusting screw 8 Cylinder head cover to cylinder head 9 Camshaft end cover to cylinder head 9 Air intake connection to cylinder head 9 Camshaft Chain sprocket to camshaft 65 Camshaft bearing cap 15 Rotary breather Vent line to alternator mount cover M 8 screw 20 Banjo screw 25 Alternator mount cover M 6 screw 9 M 8 screw 20 Auxiliary shaft Chain sprocket to crankshaft 10 Chainwheel to auxiliary shaft 70 Chain tensioner housing to engine block 9 00 4 11 Engine Oil filter Oil filter 11 Oil drain plug 32 Oil pump Mesh filter basket to engine block 9 Oil pump cover 9 Pressure relief valve 35 Oil pressure switch 30 Oil cooler Oil cooler pipe to engine block 10 Cooling oil line banjo screw with oil vent valve 25
42. 1 X Tightening torque M 6 screw 10 Nm Install drive shaft chain with chainwheel 2 and rotor 3 X Tightening torque Retaining screw at chainwheel 70 Nm Install secure chain guide rail 4 Install secure chain tensioner rail 5 Install chain tensioner housing 6 with piston and spring X Tightening torque M 6 screw 9 Nm Tighten down cooling oil line 7 e Caution Use a new sealing ring X Tightening torque M 6 screw 10 Nm Banjo screw for cooling oil line with oil vent valve 25 Nm 11 5 640 RS110250 4 2 3 1 5 6 7 11 53 Installing piston Turn joint in oil scraper ring arrow so that it fac es upwards Install piston ring gap offset by 120 in each case Production locating point X install on exhaust side e Caution Ensure that retaining rings are properly seated on piston pin Oil the sliding contact faces Always use pistons of the same weight class in any one engine Markings or a See Technical data e Caution Always install pistons and cylinders in pairs Do not accidentally confuse pistons or piston pins Piston size
43. 22 Wear limit mm in 0 17 0 007 Valve spring Spring length off load mm in 41 1 1 62 Wear limit mm in 39 0 1 54 Rocker Bore dia mm in 16 016 16 027 0 6306 0 6310 Rocker shaft dia mm in 15 973 15 984 0 6289 0 6293 Radial clearance mm in 0 032 0 054 0 0016 0 0021 Wear limit mm in 0 1 0 004 Axial play min mm in 0 05 0 002 max mm in 0 40 0 016 Camshaft Opening angle inlet exhaust cams 256 256 Cam spread inlet exhaust 106 109 Marking Marking in position 2 Inlet valve lift mm in 8 23 valve clearance 0 Exhaust valve lift mm in 8 23 valve clearance 0 Camshaft bearing bore dia mm in 21 02 21 04 0 8276 0 8284 Camshaft dia mm in 20 97 21 00 0 826 0 827 Radial clearance mm in 0 02 0 07 0 0008 0 0028 Wear limit mm in 0 15 0 006 Width of guide bearing mm in 15 92 15 95 0 6268 0 6280 Width of camshaft bearing mm in 16 0 16 05 0 630 0 632 Axial play mm in 0 08 0 13 0 0031 0 0051 Wear limit mm in 0 25 0 010 11 8 Technical data R 850 C R 1200 C Bucket type tappet Extl dia mm in 23 947 23 960 0 9428 0 9433 Bore dia in cylinder head mm in 24 000 24 021 0 9449 0 9457 Radial clearance mm in 0 040 0 074 0 0016 0 0029 Wear limit mm in 0 18 0 007 Auxiliary shaft Bore dia in crankcase front back mm in 25 02
44. 35 M6 x 35 M6 x 35 M6 x 35 M6 x 35 M6 x 50 M6 x 25 M6 x 50 11 40 Removing crankshaft auxiliary shaft and timing chain tensioning and slide rails RS110290 11 41 Removing and installing oil pick up basket X Tightening torque M 6 screw 9 Nm e Caution Make sure that the O ring is not omitted and is in stalled undamaged Replacing oil level sight glass Pierce the plastic disc with a large screwdriver and lever out the oil level sight glass Coat the sealing face of the new oil level sight glass with engine oil and drive it in with drift BMW No 00 5 550 Removing conrods Clamp crankshaft in a vise provided with protec tive jaws Remove conrod e Caution Do not accidentally confuse the conrods Checking conrods Check conrod dimensions a See Technical data e Caution Sintered metal conrods must never be straightened risk of fracture RS110300 11 42 Measuring main and big end bearing play Measuring radial bearing play Measure main bearing journal with an external micrometer crosswise in two planes A and B Enter measured values on record sheet a See Technical data e Caution The crankshaft can only be reground in grinding stage 0 after this it must be rehardened and fin ished Grinding stages are ide
45. Clutch fluid DOT 4 brake fluid Clutch plate dia mm in 165 6 50 Wear dimension mm in 4 6 0 18 measured on rivets of clutch plate using tips of sliding caliper pressed together by hand 21 4 21 5 Removing and installing clutch Removing clutch a Preparatory work is as for Removing gearbox see Group 23 Lock the clutch housing with special tool BMW No 11 5 640 Remove the clutch Installing clutch Install clutch housing with mark 1 aligned with crankshaft mark 2 Lock the clutch housing with special tool BMW No 11 5 640 e Caution Always use new bolts for housing and cover Insert all screws by hand and tighten down X Tightening torque Clutch housing to crankshaft oil screw threads lightly Initial tightening 40 Nm Wrench angle 32 Install clutch e Caution Offset the color marks on the clutch housing driven plate and housing cover through 120 in each case Secure the clutch with the retaining screws Center the clutch plate with centering pin BMW No 21 2 673 Tighten retaining screws alternately in a cross wise pattern Lubrication points Splines on clutch plate and gearbox input shaft Diaphragm spring contact surface on clutch hous ing Diaphragm spring contact surface on pressure plate Opti
46. EP2 Checking function of side prop stand contact switch Inspections I II III and IV Place the motorcycle on the auxiliary stand BMW No 00 1 550 Select a gear and switch on the ignition Slowly extend the side prop stand and watch the neutral indicator light L Note As the stand is extended the neutral indicator light should come on briefly C000200 00 26 Tightening cylinder heads Inspection I Remove cylinder head cover e Caution Trap escaping oil Select a gear and turn the rear wheel or set the piston to TDC on the ignition stroke by turning the belt pulley Top dead centre on ignition stroke The OT TDC mark is visible and the inlet and ex haust valves in the cylinder concerned are closed Tighten cylinder head nuts Tightening procedure after 1 000 km 600 miles 1 Tighten the cylinder head nuts one after the other in a crosswise pattern 1 1 Slacken off one nut at a time 1 2 Tighten nut to initial torque 20 Nm 1 3 Tighten nut to specified wrench angle 180 2 Unfasten retighten M10 screw 40 Nm Checking adjusting valve operating clearances Inspections I II and III Check valve clearance with feeler gauge and if necessary correct with adjusting nut lock Adjust valve clearances with the engine cold max 35 C 95 F Inlet 0 15 mm 0 006 in Exhaust
47. Note Valve guides are installed in the cylinder head with an interference fit of 0 015 0 044 mm 0 0006 0 0017 in If valve guide bore is undamaged and dimen sions are within correct 12 5 H7 tolerance range Use original 12 5 U6 12 533 12 544 mm 0 4934 0 4939 in valve guide Measure valve guides with micrometer If valve guide bore is undamaged but slightly larger than the 12 5 H7 tolerance range Use replacement valve guide 12 550 12 561 mm 0 4941 0 4945 in If valve guide bore is damaged or not to correct dimensions in 12 5 H7 tolerance range Use an oversize 12 7U6 12 733 12 744 mm 0 5013 0 5017 in valve guide Repair method 1 ream out the bore if bore is damaged or not to correct dimensions Determine actual diameter of valve guide using micrometer Open out bore with 12 7 H7 mm 12 700 12 718 mm 0 5000 0 5007 in ream er Repair method 2 lathe turn the valve guide bore must not be damaged Determine actual diameter of bore with internal measuring tool Calculate the nominal diameter of the valve guide Nominal diameter of valve guide bore dia inter ference fit value 0 015 0 044 mm 0 0006 0 0017 in Use an oversize 12 7 U6 12 733 12 744 mm 0 5013 0 5017 in valve guide Turn down oversize valve guide to nominal di mension Slowly heat cylinder head to 200 C 392 F in a suitable oven Immerse valve guide in
48. R 850 C R 1200 C Repair Manual Introduction This repair manual will help you to perform all the main maintenance and repair work correctly and efficient ly It should be consulted regularly by workshop personnel as an addition to the practical and theoretical knowledge obtained in Training School courses It is a contribution towards achieving even higher Service quality A new issue of this repair manual will be published if amendments or additions supplements are needed The latest issue date is shown in the header of the microfiche Microfiches rendered invalid by the new issue should be destroyed without delay All information in both text and illustrations refers to motorcycles in standard condition or with Original BMW accessories installed and not to motorcycles which have been modified in any way to depart from the man ufacturer s specification The repair manual is structured in the logical sequence of the work to be performed Removal Disman tling Repair Assembly Installation The entire contents are divided into individual chapters corresponding to the Construction Groups 11 10 Chap Page number within chapter Work to be performed during an Inspection is described in Group 00 The various Inspection routines are numbered I II III and IV This numbering is repeated in the work descriptions which follow so that work can take place without interruption Use of the BMW special tools needed
49. aded pin Install cover 11 Attach lead 1 Checking starter motor Test with MoDiTeC Checking starter relay Test with MoDiTeC RS120080 9 15 13 11 10 2 5 8 7 4 14 6 1 3 12 12 10 Removing and installing magnetic gate Remove seat Unscrew fuel tank mount Pull fuel tank to the rear and support it at the front with a piece of wood or similar e Caution Avoid scratching any components for instance by inserting a piece of cloth between the fuel tank and the frame Remove the horn with its holder Remove front cover from engine Unscrew alternator mount 1 Remove rotary breather tube 2 Remove Poly V belt 3 e Caution Disconnect ground earth lead from battery Insulate the ground earth lead Remove the starter motor Lock clutch housing with special tool BMW No 11 5 640 Remove Poly V belt pulley 4 with rotor gate at crankshaft Separate the plug connection for the magnetic trigger in the central electrical equipment box L Note If necessary mark position of magnetic trigger for later installation Remove magnetic trigger 5 Install in reverse order of work Attach rotor 6 of Hall effect gate with adhesive to the Poly V belt pulley 4 Adhesive Loctite instant adhesive or equivalent e Caution Install retainer for Hall effect rotor at groove crank shaft 7
50. ainer strong 33 17 2 331 095 10 ml bottle Loctite 454 Cyanacrylate adhesive gel 07 58 9 062 157 20 g tube Cleaner Brake cleaner Brake cleaner 83 11 9 407 848 600 ml aerosol Metal Polish Polish for chromium plated parts 82 14 9 400 890 100 g tube Testing agent Penetrant MR 68 Crack testing agent for aluminum housings 83 19 9 407 855 500 ml spray Entwickler MR 70 Crack testing agent for aluminum housings 81 22 9 407 495 500 ml spray 00 10 00 11 Key to maintenance intervals BMW Inspection 1000 km 600 miles I BMW Service II BMW Inspection III BMW Annual Service IV Reading out MoDiTeC fault memory Inspections I II III and IV Remove the left air cleaner trim panel Connect MoDiTeC to diagnostic plug Read out the fault memory Perform any repair work indicated Checking throttle cable play adjusting if necessary Inspections I and III Check throttle cable for free movement and free dom from abrasion or kinking renew if neces sary With the steering turned to various angles open the throttle twistgrip fully and allow it to close again When released the twistgrip must return to the closed position by itself Pull back the protective cap Preset throttle cable play with the engine cold to 1 5 mm 0 06 in Warm the engine up to its regular operating tem perature Adjust throttle cable play to 0 5 mm 0 02 in Adj
51. al electrical equipment Horn to holder 13 Ground earth strap to engine block 10 63 Lights Headlight to holder 15 Model R 850 1200 C Connection Nm 00 9 Table of operating fluids Item Use Order number Quantity Lubricant Optimoly MP 3 High performance lubricating paste 07 55 9 062 476 100 g tube Optimoly TA High temperature assembly paste 18 21 9 062 599 100 g tube Silicone grease 300 heavy Damping grease 07 58 9 058 193 10 g tube Retinax EP2 Wheel steering head and taper roller bearing grease 83 22 9 407 845 100 g tube Contact spray Contact spray 81 22 9 400 208 300 ml aerosol Chain spray Drive chain 72 60 2 316 676 72 60 2 316 667 50 ml spray 300 ml spray Sealants 3 Bond 1110 B Surface sealant 07 58 9 056 998 5 g tube 3 Bond 1209 Surface sealant 07 58 9 062 376 30 g tube omni VISC 1002 Surface sealant 07 58 1 465 170 90 g tube Loctite 574 Surface sealant 81 22 9 407 301 50 ml tube Curil K 2 Heat conductive sealant 81 22 9 400 243 250 g can Hylomar SQ 32 M Permanently elastic sealant 81 22 9 400 339 100 g tube Adhesives and retaining agents Loctite 648 Joint adhesive low clearance 07 58 9 067 732 5 g bottle Loctite 638 Joint adhesive greater clearance 07 58 9 056 030 10 ml bottle Loctite 243 Thread retainer medium strength 07 58 9 056 031 10 ml bottle Loctite 270 Thread retainer strong 81 22 9 400 086 10 ml bottle Loctite 2701 Thread ret
52. ast every 2 years Changing oil in rear wheel drive cleaning inductive signal transmitter at rear wheel 13 Inspections I III and IV Every 40 000 km 24 000 miles or at least every 2 years Renewing fuel filter 14 Inspection III In normal operating conditions every 40 000 km 24 000 miles if fuel quality is poor every 20 000 km 12 000 miles Checking battery acid level topping up if necessary cleaning greasing battery posts 16 Inspections III and IV Renewing intake air cleaner element 16 Inspection III In very dirty and dusty operating conditions renew every 10 000 km 6 000 miles or even more fre quently if necessary Renewing Poly V belt 17 every 60 000 km 36 000 miles Inspection III Poly V belt adjusting procedure Checking brake fluid level
53. aust 45 Valve seat width Inlet mm in 1 1 0 15 0 043 0 006 Wear limit mm in 2 5 0 10 Exhaust mm in 1 4 0 15 0 055 0 006 Wear limit mm in 3 0 0 12 Valve seat extl dia dimension for machining seat Inlet mm in 31 4 0 1 1 24 0 004 33 4 0 1 1 32 0 004 Exhaust mm in 26 4 0 1 1 04 0 004 28 4 0 1 1 12 0 004 Seat ring dia oversize 0 2 mm 0 008 in Inlet mm in 34 634 34 650 1 3635 1 3642 36 617 36 633 1 4416 1 4422 Exhaust mm in 30 134 30 150 1 1864 1 1870 32 134 32 150 1 2651 1 2658 Seat dia in cyl head oversize 0 2 mm 0 008 in Inlet mm in 34 500 34 525 1 3583 1 3592 36 500 36 525 1 4370 1 4380 Exhaust mm in 30 000 30 025 1 1811 1 1821 32 000 32 025 1 2599 1 2608 11 7 Technical data R 850 C R 1200 C Valve guide Valve guide Extl dia mm in 12 533 12 544 0 4934 0 4939 Bore in cylinder head mm in 12 500 12 518 0 4921 0 4928 Overlap mm in 0 015 0 044 0 0006 0 0017 Repair stages Replacement valve guide Extl dia mm in 12 550 12 561 0 4941 0 4945 Oversize valve guide Extl dia mm in 12 733 12 744 0 5013 0 5017 Valve guide Intl dia mm in 5 0 5 012 0 1969 0 1973 Radial clearance Inlet mm in 0 020 0 046 0 0008 0 0018 Wear limit mm in 0 15 0 006 Exhaust mm in 0 030 0 056 0 0012 0 00
54. auxiliary shaft timing chains e Caution Timing chains 2 must mesh fully with auxiliary shaft sprockets RS110291 u 2 1 11 47 Assembling engine block Coat clean grease free sealing faces arrow with 3 Bond 1209 Secure the timing chain with rubber band 1 to the timing chain tensioning and slide rail RS110920 M10 x 100 M10 x 100 M6 x 50 M6 x 50 M6 x 50 M6 x 50 M6 x 50 M6 x 50 M6 x 50 M6 x 50 M6 x 25 M6 x 25 M6 x 25 M6 x 35 M6 x 35 M6 x 35 M6 x 35 M6 x 35 M6 x 35 M6 x 50 M6 x 35 1 u 11 48 Bolt the crankcase sections together X Tightening torque tightening order 1 M10 screw oiled 45 Nm 2 M 8 screw oiled 20 Nm 3 M 6 screw 9 Nm RS110391 M10 x 100 M10 x 100 M8 x 80 M8 x 80 M8 x 35 M8 x 35 11 49 Installing the crankshaft radial seal Pre form the lip of the radial shaft seal carefuilly by hand 1 Oil the radial shaft seal at the sealing contact surface Place radial seal over sliding sleeve 2 remove sliding sleeve 3 Drive the radial shaft seal in with handle BMW No 00 0 500 and drift with sliding sleeve BMW No 11 5 660 4 RS110400 1 2 3 4 11 5 660 11 50 Installing clutch housing e Caution Always use new bolts for housing
55. cket auxiliary shaft and chain wheel crankshaft face down Locate ignition stroke TDC with insert pin BMW No 11 2 650 at hole in clutch housing and engine block L Note With engine installed adjust to TDC with dial gauge holder BMW No 00 2 650 and dial gauge BMW No 00 2 510 Left cylinder at TDC on ignition stroke Locating pin arrow on left camshaft sprocket points upwards Mark R or arrow and tip of tooth at left camshaft sprocket is aligned precisely with mark X on timing gear carrier Check setting again with timing chain tensioner installed RS110963 RS110511 X 11 59 Install the end cover with an O ring which is in good condition X Tightening torque M 6 screw 9 Nm If necessary reduce end play to a minimum by repositioning the bearings Rocker end float min 0 05 mm 0 002 in max 0 40 mm 0 016 in Install cylinder head cover e Caution Ensure that gaskets are properly seated Gaskets and sealing face must be free from oil and grease X Tightening torque Cover screw 8 Nm Tighten air intake stub pipe X Tightening torque M 6 screw 9 Nm RS110050 RS110100 RS110940 RS110440 11 60 Installing alternator mo
56. d impact weight BMW No 00 8 582 pull out the swinging arm bearing Remove the left swinging arm bearing Remove rear swinging fork Remove the rubber intake pipe sleeves Remove brake fluid reservoir from holder Remove the holder Detach the right plug holder plate Pull off the NTC air plug Detach the gear pedal at the pivot Separate the throttle potentiometer and throttle angle positioner plugs at the left plug holder plate Disconnect both fuse boxes at the plug holder plate C230180 C330030 C330040 00 8 581 00 8 582 23 6 Separate the side prop stand swithc plug Separate the neutral indicator plug Detach the left plug holder plate Remove the injectors Pull the plugs off the injector lines Disconnect the brake light switch plug and de tach the cable Detach the breather hose at the air cleaner cas ing Detach the throttle cable at the twistgrip Remove rear section of frame Detach the footrest assembly Remove the starter motor cover Detach the positive lead from the starter motor Remove the battery Unscrew rear battery mount Raise the battery holder at the rubber mount Detach the clutch slave cylinder mount and pull out of the gearbox Pull out the thrust rod Detaching the gearbox When removing pull the gearbox out on guide pins BMW No 23 1 820 Install by following the ab
57. ds lightly Additional wrench angle 32 Housing cover 12 Slave cylinder to gearbox 9 Clutch line to handlebar fitting 18 Model R 850 1200 C Connection Nm 00 6 23 Transmission Oil filler plug 23 Oil drain plug 55 Gearbox to engine block 22 Gear shift pedal to rear frame 41 Selector lever to selector shaft 9 Gearbox cover to gearbox housing 9 31 Front fork Fixed tube to fork bridge 35 free from oil and grease Slider tube bridge to slider tube 22 clean thread Loctite 243 Quick release axle clamp screws 20 Threaded journal to frame 130 clean thread Loctite 243 Ball joint to fork slider bridge 230 apply light coat of Never Seez to thread Leading link to ball joint 130 clean thread Loctite 2701 Leading link to engine right 73 Screw cap at leading link left 42 apply light coat of Never Seez to thread Spring strut to frame 40 Spring strut to leading link 40 32 Steering Handlebar at fork bridge 21 apply light coat of Never Seez to thread Twistgrip to handlebar 8 33 Rear wheel drive Oil filler plug 23 Oil drain plug 23 Threaded ring 118 Hylomar SQ 32 M Hexagon nut input bevel gear 200 clean thread Loctite 2701 Cover at rear wheel drive housing 35 Rear wheel drive to swinging arm 24 Swinging arm bearing journal to rear frame right 9 Swinging arm bearing journal to rear frame left 7 clean thread Loctite 2701 Loc
58. e cold max 35 C 95 F Inlet 0 15 mm 0 006 in Exhaust 0 30 mm 0 012 in X Tightening torque Locknut 8 Nm Check valve clearance again it must be possible to insert the feeler gauge between valve stem and rocker with only slight resistance to move ment RS110980 11 57 Installing right cylinder head Adjustment specification e Caution When assembling always start with the right cylin der Right cylinder at TDC on ignition stroke marks arrows on chainwheel auxiliary shaft and chain sprocket crankshaft are aligned Locate ignition stroke TDC with insert pin BMW No 11 2 650 at hole in clutch housing and engine block L Note With the engine installed adjust TDC with dial gauge holder BMW No 00 2 650 and dial gauge BMW No 00 2 510 Right cylinder at TDC on ignition stroke Locating pin arrow on right camshaft sprocket points downwards Mark R or arrow and tip of tooth on right camshaft sprocket is precisely aligned with mark X on timing gear carrier Check setting again with timing chain tensioner installed RS110961 RS110150 X 11 58 Installing left cylinder head Adjustment specification e Caution When installing always begin with the right cylin der Left cylinder TDC on ignition stroke marks ar rows on chain spro
59. e oil grade Brand name HD oil for four stroke spark ignition en gine API classifications SE SF SG combination with CC or CD specification C000240 C000030 11 4 650 00 13 Changing oil in gearbox Inspections III and IV or at least every 2 years Change the gearbox oil while at regular operating temperature Loosen clip trim 1 at right silencer and turn downwards Take out oil filler plug 3 and oil drain plug 2 and allow the oil to drain out Clean the magnet in the oil drain plug Insert the oil drain plug again L Note Add oil to the gearbox up to the lower edge of the filler hole then place the motorcycle on its side prop stand and add the remaining 0 2 litre 0 35 Imp pint 0 21 US quart Add gearbox oil Insert oil filler plug with new seal X Tightening torque Oil drain plug 55 Nm Oil filler plug 23 Nm Exhaust pipe clip at silencer muffler 55 Nm Fill quantity Initial filling 1 0 l 1 76 Imp pints 1 06 US quart During oil changes 1 0 l 1 76 Imp pints 1 06 US quart Oil grade for gearbox Brand name hypoid gear oil SAE 90 API class GL 5 Changing oil in rear wheel drive cleaning inductive signal transmitter at rear wheel Inspections I III and IV Every 40 000 km 24 000 miles or at least every 2 years Change the gearbox oil
60. e right and pull the shaft out to the left Remove the leading link Detach the hose for the oil cooler at the engine Remove frame Install by following the above work instructions in the reverse order 11 18 Dismantling engine Attach engine mount BMW No 11 0 630 to the engine block Transfer engine to assembly frame Drain engine oil Remove the oil filter using oil filter wrench BMW No 11 4 650 00 0 630 RS110010 11 4 650 RS110950 11 19 Removing cylinder head cover Unscrew and remove spark plug with the spark plug wrench BMW No 12 3 510 Remove cylinder head cover e Caution Trap escaping oil 12 3 510 RS110020 11 20 Locking the engine in the TDC position Remove front cover Turn the belt pulley to move the piston to TDC on the ignition stroke Top dead centre on ignition stroke 1 TDC mark is visible and 2 The inlet and exhaust valves in the cylinder in question are closed Prevent the clutch housing from moving with locking device BMW No 11 5 640 L Note The engine can be correctly positioned at TDC with locating pin BMW No 11 2 650 through the hole in the clutch housing and the engine block RS110030 11 5 640 TDC RS110461 11 2 650 TDC 11 21 Removing and installing chain tensioner e Caution Do not accidentally confuse the chain tensioner pis tons When installing fit a new gasket Assembly
61. eC 1 2 3 RS120050 12 8 Removing and installing starter motor e Caution Disconnect earth ground lead from battery Insulate earth ground lead Release starter motor cover 1 Remove the cover Detach lead 2 Release starter motor retainer 3 Remove the starter motor Install by following the above work instructions in the reverse order X Tightening torque Starter motor to engine 20 Nm Starter motor cover to gearbox housing 7 Nm Positive lead to starter motor 10 Nm C120020 1 3 2 12 9 Dismantling reassembling starter motor Detach lead 1 Remove retaining screws 2 Remove flange 3 Remove solenoid switch 4 after taking out the retaining screws 5 Remove release lever 6 and spring 7 from so lenoid switch 8 Remove retaining ring 9 and take starter motor gear assembly 10 off shaft Install by following the above work instructions in the reverse order Coat the helical thread and pull in ring with grease Lubricant Bosch PZ 2 V 3 silicone grease or equivalent Renewing carbon brushes Detach lead 1 Remove cover 11 Remove holder 12 for carbon brushes Lift up retaining springs 13 and remove carbon brushes 14 Install carbon brushes with retaining plate Slide short lead 15 on to thre
62. ect the brake bleeding device to the bleed screw on the right brake caliper Open the bleed screw by half a turn Draw off brake fluid until it emerges clear and free from air bubbles Close the bleed screw on the right brake caliper Repeat the bleeding process at the left brake caliper When installing L Note Clean the rim of the reservoir the rubber gaiter and the cover to remove brake fluid and re assemble the components with great care e Next check brake fluid level with the motorcy cle on its side prop stand and the handlebar turned to the left and ensure that no air bubbles are visible in the sight glass C000150 34 1 500 KR340280 00 22 Additionally with ABS Connect the brake bleeding device to the pres sure modulator for the front brake arrow this is marked VR Open the bleed screw by half a turn Draw off brake fluid until it emerges clear and free from air bubbles Close the bleed screw Bleed the left brake caliper in precisely the same way as on the right If necessary repeat the brake bleeding proce dure at the right left X Tightening torque Bleed screw on pressure modulator 9 Nm Take out the resetting tool and insert spacer BMW No 34 1 520 in its place Press the pistons back in the second brake cali per but do not remove the resetting tool Fill and bleed the front brake circuit Installation takes place in t
63. ecting leads at the alternator Remove the alternator Install by following the above work instructions in the reverse order Poly V belt adjusting procedure Poly V belt installation procedure Place the Poly V belt in position tension it and turn the engine over once then release belt ten sion Poly V belt tensioning procedure Loosen alternator mount 1 2 3 Screw up hex nut 1 at adjusting screw 4 lightly by hand using no tools Tighten adjusting screw 4 using torque wrench fully tighten retaining nut 3 slacken off adjusting screw and tighten down screws L Note See also Service Information 12 020 95 700 X Tightening torque Poly V belt preload 8 Nm Alternator to alternator support cover 20 Nm Positive lead to alternator 15 Nm Belt pulley at alternator 50 Nm RS110480 4 1 3 2 12 7 Dismantling reassembling alternator Take out the cover retaining screws 1 Release clips 2 and remove the cover Remove voltage regulator 3 Remove the Poly V belt pulley Install by following the above work instructions in the reverse order X Tightening torque Belt pulley at alternator 50 Nm Checking alternator Test with BMW MoDiTeC Checking armature for short to ground earth Test with BMW MoDiT
64. ed with oil cooled exhaust ports installed longitudinal ly 4 valves per cylinder two high mounted camshafts electronic fuel injection Location of engine number Crankcase Cylinder bore mm in 87 5 3 44 101 3 97 Stroke mm in 70 5 2 77 73 2 87 Effective displacement cc 848 1170 Compression ratio 10 3 1 10 0 1 Power output kW bhp min 1 37 50 5250 45 61 5000 Max torque Nm min 1 71 4750 98 3000 Permissible maximum engine speed min 1 7000 Idle speed min 1 750 150 Direction of rotation Clockwise looking at ignition system Compression test pressure good normal poor bar psi bar psi bar psi bar psi above 10 142 8 5 10 121 142 below 8 5 121 Intake port dia cylinder head mm in 45 1 77 Lubrication system Theoretical volume in circulation at 6000 min 1 Lubricating oil Cooling oil l Imp gal US gal l Imp gal US gal 36 7 92 9 51 30 6 60 7 93 Oil filter Full flow type Pressure differential needed to open bypass valve bar psi 1 5 21 3 Oil pressure warning light comes on below bar psi 0 2 0 5 2 8 7 1 Pressure relief valve opens at bar psi 5 5 78 3 Operating pressure bar psi 3 5 6 0 49 8 85 4 Oil content Without filter change With filter change min max l Imp pint US quart l Imp pint US quart l Imp pint US quart 3 50 6 2 3 69 3 75 6 6 3 96 0 5 0 88 0 53
65. ets e Caution Do not accidentally confuse the bucket type tap pets Reassemble in the reverse order of work e Caution Note direction of installation 3 for camshaft bearing cap The cutout on the rocker shafts must be aligned with the retaining holes L Note Locate pushrods in ball cups on rockers and hold the rockers together with a rubber band to secure the pushrods in position X Tightening torque M 8 screw rocker shaft bearing cap 15 Nm M 8 screw for camshaft bearing cap 15 Nm Reposition the bearings until minimum endplay is obtained End float of rocker min 0 05 mm 0 002 in max 0 40 mm 0 016 in RS110090 3 1 M8 x 65 2 RS110100 11 25 Removing cylinder head RS110110 M6 x 30 M6 x 30 M6 x 30 M10 x 70 11 26 Dismantling checking repairing and re assembling cylinder head Removing and installing valves e Caution Do not scratch sealing face on cylinder head Place the head on a clean scratch free surface Attach valve spring tensioner BMW No 11 5 690 to cylinder head Clamp the valve springs Separate valve collet from spring plate by striking the valve head gently Remove valve collet sections Relieve tension on valve springs Remove top bottom spring plates valve springs and valves Removing valve stem seals Pull off
66. for certain tasks is described in the work instructions If the need arises repair instructions are also issued in the form of Service Information This information is of course incorporated into the next issue of the repair manual We also recommend you to consult the detailed illustrations on the Parts microfiches as an additional source of information BMW AG Motorcycle Division After Sales Order No 01 71 0 008 872 UX VS 2 06 99 Printed in Germany Customer Licence plate No Order No Mechanic s signature BMW Inspection at 1000 km 600 miles BMW Service every 10 000 km 6 000 miles BMW Inspection every 20 000 km 12 000 miles BMW Annual Service Read the fault code memory with the MoDiTeC Change oil while at regular operating temperature and renew the oil filter element if motorcycle is used only for short journeys or at outside temperatures under 0 C 32 F every 3 months but at least every 3 000 km 1 800 miles Change oil in gearbox while at operating temperature at least every 2 years every 2 years Change oil in rear wheel drive while at regular operating temperature if necessary clean inductive sensor on rear wheel every 40 000 km 24 000 miles or at least every 2 years 40 000 24 000 every 2 years Renew fuel filter normally every 40 000 km 24 000 miles if fuel quality is poor every 20 000 km 12 000 miles 40 000 24 000 Check battery acid leve
67. g stage 0 grinding stage 1 0 25 mm 0 010 in Crankpin dia mm in 47 975 47 991 1 8888 1 8894 Bearing width of crankpin mm in 22 065 22 195 0 8687 0 8738 11 9 Technical data R 850 C R 1200 C Connecting rod Bore dia for big end bearing mm in 51 000 51 013 2 0079 2 0084 Big end bearing dia mm in 48 016 48 050 1 8904 1 8918 Radial clearance mm in 0 025 0 075 0 0010 0 0030 Wear limit mm in 0 13 0 0051 Width of big end bearing eye mm in 21 883 21 935 0 8616 0 8636 Conrod end float mm in 0 130 0 312 0 0051 0 0123 Wear limit mm in 0 5 0 02 Small end bearing bore dia mm in 22 015 22 025 0 8667 0 8671 Radial clearance mm in 0 015 0 030 0 0006 0 0012 Wear limit mm in 0 06 0 002 Distance between centers mm in 125 4 92 Max deviation from parallel of conrod bores at 150 mm 5 90 in spacing mm in 0 07 0 003 Cylinders Bore 20 mm 0 79 in from top edge A mm in 87 492 87 500 3 4446 3 4449 100 992 101 000 3 9761 3 9764 Wear limit mm in 87 550 3 4468 101 050 3 9784 B mm in 87 500 87 508 3 4449 3 4452 101 000 101 008 3 9764 3 9768 Wear limit mm in 87 558 3 4471 101 058 3 9787 Total wear clearance of piston and cylinder mm in 0 12 0 005 Permitted out of roundness of cylinder bore 20 mm 0 79 in from the top edge mm in 0 03 0 0012 10
68. haft sealing ring Install the new sealing ring with the sealing lips facing inwards using guide pin BMW No 23 4 722 and impact driver BMW No 23 4 721 Renewing shaft sealing ring for selector drum Lever the shaft sealing ring out with a screw driver Install the new sealing ring with the sealing lips facing inwards using impact driver BMW No 23 4 750 Renewing sealing ring for selector shaft Lever the shaft sealing ring out with a screw driver Install the new sealing ring with the sealing lips facing inwards using slip over sleeve BMW No 23 4 612 and impact driver BMW No 23 4 740 C230160 23 4 612 23 4 740 23 4 750 00 8 581 23 4 721 23 4 722 00 8 583 00 8 582 23 9 Dismantling gearbox Removing gearbox housing Take out oil filler level check screw 2 Take out oil drain plug 7 and drain the oil out of the gearbox into a suitable tray Remove breather 1 Unclip cable 3 for neutral indicating switch 4 Compress spring 5 and take off neutral indicat ing switch 4 Remove selector lever 6 Carefully press back centering pins arrows working from the back of the gearbox Remove screws 8 securing cover to housing Set the gearbox down on its cover e Caution Avoid damage to the housing cover and painted sur faces Heat the bearing points in the housing to 80 C 100 C 176 F 212 F Str
69. haust system 3 Removing and installing silencer muffler 3 Removing and installing front exhaust pipes 3 18 Exhaust system 18 2 18 3 18 Removing and installing exhaust system Removing and installing silencer muffler Unscrew fuel tank and pull to the rear Separate the plug connection for the oxygen sensor and detach the wire e Caution Do not pull the oxygen sensor cable Loosen the retaining clips Pull off the silencer muffler Install by following the above work instructions in the reverse order When installing align the hole arrow on the clip with the embossed dot arrow on the silencer muffler e Caution Note position of wiring for oxygen sensor X Tightening torque Clip at silencer muffler apply Never Seez to the clip contact face 55 Nm Remove install the oxygen sensor 1 Secure the oxygen sensor with special socket wrench insert BMW No 11 7 020 e Caution After a trial run read out Motronic fault memory X Tightening torque Oxygen sensor coat thread with Never Seez 45 Nm Removing and installing front exhaust pipes When installing align the hole arrow in the clip with the embossed dot arrow
70. he reverse order of re moval Brake fluid grade DOT 4 X Tightening torque Brake caliper to fork tube 40 Nm Bleed screw at brake caliper 7 Nm C000160 34 1 520 C000170 00 23 Bleeding rear brake circuit renewing brake fluid L Note On motorcycles with ABS start at the pressure modulator Use the auxiliary stand BMW No 00 1 550 Loosen the rear wheel studs Remove the cover for the line at the swinging arm Take off the brake caliper Remove the inner brake pad e Caution Do not allow brake fluid to come into contact with painted parts of the motorcycle because brake fluid destroys paint Move the brake caliper to a horizontal position Connect the bleed line and open the bleed screw Force the pistons fully back with resetting tool BMW No 34 1 500 Press the brake pedal down several times until brake pressure is felt to build up Fill the rear brake circuit and bleed it Take off the reservoir cover Add brake fluid up to the MAX mark arrow Connect the brake bleeding device to the bleed screw on the brake caliper Open the bleed screw by half a turn e Caution During brake bleeding make sure that the fluid re plenishing hole is always below the level of the brake fluid or else air will be drawn into the brake system If this occurs repeat the bleeding ope
71. identification On piston crown A B AB for either A or B cylinder and on cylinder A B RS110430 X 11 54 Installing cylinder Apply 3 Bond 1209 to the cylinder base sealing face arrow which must be clean and free from grease Oil the cylinder wall Compress the piston rings with a clamping strap BMW No 11 2 900 Install the cylinder and at the same time pass the timing chain and the tensioning and guide rail through the timing case cavity Tighten cylinder down firmly Fit new seal to pivot pin for chain guide rail 1 Install chain sprocket X Tightening torque tightening order 1 M 8 screw 20 Nm 2 M 6 screw 9 Nm 3 Pivot screw for chain guide rail 18 Nm 11 2 900 RS110420 1 u 11 55 Installing cylinder head Install cylinder head gasket Fit cylinder head insert correctly positioned cam shaft chain sprocket 1 and timing chain into chain cavity Install valve gear support 2 Tighten cylinder head down e Caution Install collar arrow of cylinder head nut towards cyl inder head X Tightening torque tightening order 1 Tighten cylinder head nuts oiled crosswise 1 1 Tighten all nuts 20 Nm 1 2 Tighten all nuts to correct angle 90 1 3 Tighten all nuts to correct angle
72. ike lightly with a plastic faced hammer to re lease the gearbox C230012 1 4 7 6 5 3 8 2 C230020 h 80 100 w 23 10 Removing selector drum Pull the selector shafts 1 out of the selector forks Swing the selector forks 3 8 out towards the edge of the cover arrows Remove locking pin 9 Press guide plate 5 in the opposite direction to the spring loading arrow Swing locking lever 6 towards input shaft 7 hold it there and pull out the selector drum 4 turning it slightly at the same time Remove the thrust washers and spacing washer Release the locking lever 6 Remove the selector shaft 7 with spacing wash er Remove selector forks 3 Selector fork 8 remains in the intermediate shaft 10 Dismantling assembling selector shaft Remove torsion spring 5 with locking lever 4 from selector shaft 2 Remove torsion spring 1 Remove coil spring 6 and take off together with sliding plate 3 Assemble in the opposite order of work C230030 1 7 9 10 1 8 5 3 6 4 2 KR230050 1 2 3 4 5 6 23 11 Removing gearbox shafts Remove breather tube 3 Heat bearing points in gearbox cover to 80 C 100 C 176 F 212 F Take off input shaft 4 output shaft 1 and intermediate shaft 5 together from the cover Remove selector fork 2 from
73. intermediate shaft Renewing deep groove ball bearing on intermediate shaft e Caution If the deep groove ball bearings are renewed the fully compressed length must be re adjusted Pull off the deep groove ball bearings with a uni versal puller BMW No 00 7 500 Press the output side deep groove ball bearing on to the intermediate shaft Check adjust fully compressed length a 23 17 Place the spacing washer of the determined thickness in position and press on the input side deep groove ball bearing C230040 1 4 5 h 80 100 w 2 3 00 7 500 KR230070 23 12 Dismantling assembling input shaft Dismantling input shaft Clamp the input shaft into the vise using soft jaws Use universal puller BMW No 00 7 500 and pressure head arrow to pull off deep groove ball bearing 9 with spacing washer 8 Note the thickness of spacing washer 8 Remove guide ring 7 Compress spring cluster 4 and remove split segment washer 6 Remove support disc 5 spring cluster 4 anti rattle disc 3 thrust block 2 and constant speed gear 1 Transfer input shaft 10 to a different position Use universal puller BMW No 00 7 500 and pressure head arrow to pull off deep groove ball bearing 11 11 10 KR230080 9 8 7 6 5 4 3 2 1 00 7 500 KR230090 9
74. knut at swinging arm bearing journal 160 Suspension strut to rear frame 50 Suspension strut to rear swinging arm 50 Model R 850 1200 C Connection Nm 00 7 34 Brakes Brake caliper at fork slider tube 40 Brake caliper to rear wheel drive 40 Brake disc to front wheel 24 clean thread Loctite 2701 34 Brakes Brake disc to rear wheel drive 21 clean thread Loctite 2701 Master cylinder to footrest assembly 8 Brake pedal to footrest assembly 37 Brake lines brake hose to brake components 18 ABS sensor 4 handtight Front brake caliper bleed screw 7 Rear brake caliper bleed screw 4 Pressure modulator bleed screw 9 36 Wheels and tyres Quick release axle clamp screws 20 Quick release axle threaded connection 30 Rear wheel to rear wheel drive Screw wheel studs in handtight then tighten in a crosswise pattern Initial tightening 50 Final tightening 105 Model R 850 1200 C Connection Nm 00 8 46 Frame Frame to engine M12 pin 82 M10 screw 58 Rear frame to engine 41 to gearbox 71 Side prop stand pivot mount to engine 21 Side prop stand to pivot mount 42 clean thread Loctite 243 Footrest assembly to engine M12 screw 71 M8 screw 21 Pillion footrest holder to rear frame 21 Pillion seat mount 21 Mudguard to slider tube bridge 8 51 Equipment Mirrors 15 Ignition steering lock to fork bridge 15 shear bolt 61 Gener
75. l if necessary add distilled water Clean and grease the battery terminals if necessary Renew intake air filter element in very dusty or dirty operating conditions renew the intake air filter element every 10 000 km 6 000 miles or even more often if necessary Renew Poly V belt renew Poly V belt every 60 000 km 36 000 miles do not adjust 60 000 36 000 Check brake fluid level at front and rear and top up if necessary Check operation of brake system and freedom from leaks repair replace items if nec Examine brake pads and discs for wear renew if necessary Change the brake fluid annually Check clutch fluid level Change the clutch fluid every 40 000 km 24 000 miles or at least every 2 years 40 000 24 000 every 2 years Check tightness of rear wheel studs Check rear wheel bearing play by tilting wheel Check swinging arm bearings zero play adjust if necessary Grease the side stand pivot Check function of side stand contact switch Check condition of spark plugs Renew spark plugs Check security of cylinder head nuts Check adjust valve clearances Check throttle cable for free movement abrasion and kinking renew if necessary Check cable play Check synchronisation and eliminate leaks Final inspection with road safety and functional check Condition of tyres and wheels rims and spokes if applicable tyre pressures Lights and signalling equipment
76. liquid grinding paste Freeze valve guide with dry ice e Caution Immediately before pressing in the temperature must be 40 C 40 F Place heated cylinder head flat on workbench or a similar surface After cooling place the valve guide on driving in pin driving in pin 5mm 0 20 in BMW No 11 5 673 Insert valve guides into cylinder head with no de lay Allow cylinder head to cool down to room tem perature app 20 C 68 F Inspect bore in valve guide L Note Valve guides for repair purposes are produced with an internal diameter of 5 01 mm 0 1972 in H7 In most cases the bore is within the 5 00 mm 0 1969 in H7 tolerance range after pressing in If the bore is too narrow ream it out to size 11 29 Installing valve and valve stem seal L Note If a valve was removed the valve stem seal must be renewed Oil the stem when installing the valve Shrink a short length of tube arrow on to the end of the valve stem Install the valve stem seal with a 5 mm 0 20 in dia drift BMW No 11 5 602 e Caution Remove the shrunk on tube Fit lower spring plate valve spring and upper spring plate Compress the valve springs with the valve spring clamp BMW No 11 5 690 L Note Insert the taper valve collets using grease to simpli fy assembly e Caution Ensure that valve collets are correctly seated in the valve stem grooves Relieve tension o
77. ment box Remove the brake lines from the pressure mod ulator to the front junction box Detach the lines at the pressure modulator Remove the ABS unit e Caution Comply exactly with the instructions in the Repair Manual aGroup 34 Remove battery carrier Remove the horn Remove the ignition coil Pull off the plug cap with special puller BMW No 12 3 520 and remove the ignition lead Open the headlight housing Detach the headlight cable Detach the flashing turn indicator wires Detach the oil pressure switch wire Detach the alternator cables C330050 RS230010 23 1 820 C340011 11 17 Detach the central earth ground wire at the en gine block Remove the left air intake pipe at the cylinder head Heat the ball joint mount at the leading link to max 120 C 248 F and detach it e Caution Do not scratch the surface of the leading link Detach the line for the front brake caliper at the junction block frame Remove the caps from the threaded connections on the fixed tubes Separate the fixed tube from the fork bridge at the threaded connections Remove the telescopic fork Remove the cover plate over the upper suspen sion strut mount on the frame Remove suspension strut Remove the leading link caps Remove the left screw cap Remove the circlip at the right and the safety cap Take out the screw at th
78. moly MP3 paste X Tightening torque Housing cover to flywheel 12 Nm 11 5 640 C210010 1 2 21 6 Removing and installing clutch hydraulic line Remove fuel tank Remove the battery ABS Drain the brake system e Caution Do not allow brake fluid to come into contact with painted parts of the motorcycle because brake fluid destroys paint ABS Remove the ABS unit Remove battery carrier Drain the clutch operating system e Caution Do not allow brake fluid to come into contact with painted parts of the motorcycle because brake fluid destroys paint Detach the clutch line at the separating point 1 Detach the clutch slave cylinder and pull it to the rear with the line Detach the lines at the clutch slave cylinder Install by following the above work instructions in the reverse order Fill the clutch operating system ABS Add fluid to brake system L Note When installing fit new sealing rings X Tightening torque Clutch line to handlebar fitting 18 Nm Removing and installing clutch slave cylinder Remove fuel tank e Caution Do not allow brake fluid to come into contact with painted parts of the motorcycle because brake fluid destroys paint Detach clutch line at separating point 1 Detach and raise the central electrical equipment box at the left Detach the clutch slave cylinder a
79. motorcycle on the auxiliary stand BMW No 00 1 550 Turn the steering to the right e Caution With the clutch lining in new condition the surface of the fluid arrow must be up to the lower edge of the ring mark it must not be below normal L Note As the clutch lining wears the fluid level in the res ervoir rises If necessary take off reservoir cover with insert Correct the fluid level Mark in reservoir as for brake circuit Re attach the reservoir cover with insert Tighten the reservoir cover without using force Brake fluid grade DOT 4 C000190 CUB0100 00 25 Checking tightness of rear wheel studs Inspection I Tighten the rear wheel studs with a torque wrench X Tightening torque Rear wheel studs 105 Nm Checking rear wheel bearing play by tilting wheel Inspection III Tilt the rear wheel to and fro across its axle If play is detected fit new shims to rear wheel drive or renew bearings Checking swinging arm bearings adjusting if necessary Inspections I and III Grip rear tyre and try to move it sideways brac ing against the frame Greasing the side prop stand pivot Inspections I II and III Check free movement of side prop stand and grease if necessary Grease pivot point arrow Lubricant For side prop stand pivot Shell Retinax
80. n valve springs Check valves for leakage blow by 11 5 690 RS110160 11 5 602 11 30 Removing cylinder barrel Unscrew and remove guide rail bearing screw 1 Unscrew and remove cylinder retaining screws and remove cylinder e Caution When removing cylinder ensure that the piston does not strike the engine block Removing dismantling piston Remove both retaining rings on piston pin Press out piston pin by hand Remove piston Carefully remove piston rings with piston ring pliers Remove carbonized oil from base of piston clean the piston e Caution Do not accidentally confuse pistons piston pins or piston rings RS110170 1 11 31 Checking pistons and cylinders Reference temperature for measurements 20 C 68 F Measure cylinder bore with internal probe at 20 mm 0 79 in and 100 mm 3 94 in from the top in direction of piston pin and again at a right angle to the first measurement a See Technical data Measuring plane A 6 mm 0 24 in a See Technical data Install piston rings in cylinder Determine piston ring clearance using feeler gauge a See Technical data Assembling pistons Carefully fit piston rings to piston in the following sequence using piston ring pliers
81. nd pull it to the rear with the line Detach lines at clutch slave cylinder Remove clutch slave cylinder Install by following the above work instructions in the reverse order Fill the clutch operating system L Note When instaling fit new sealing rings X Tightening torque Clutch slave cylinder to gearbox 9 Nm C210030 1 2 21 7 Filling bleeding clutch line e Caution Do not allow brake fluid to come into contact with painted parts of the motorcycle because brake fluid destroys paint L Note The description applies to a brake system filling and bleeding device with vacuum extraction of brake flu id at the bleed line If other devices are used comply with their manu facturers instructions Take off reservoir cover with rubber diaphragm Standard handlebar Police Raise motorcycle on auxiliary stand BMW No 00 1 560 and swing handlebar fully to right Optional handlebar Easy Rider Prop motorcy cle on side stand and turn handlebar fully to right e Caution With the clutch lining in new condition the surface of the fluid arrow must be up to the lower edge of the ring mark it must not be below normal L Note As the clutch lining wears the fluid level in the res ervoir rises Top up the brake fluid Bleed the clutch line through bleed screw 2 e Caution During the bleeding operation the brake fluid must not drop below the MIN mark o
82. ntified by a paint mark on the front crank web a See Technical data If the bearing shells have to be replaced note color ed marks on crankpins and big end bearings RS110310 11 43 Installing main bearing Insert tensioner rail slide rail pivot pin 1 for centering purposes Tighten M8 and M10 housing screws X Tightening torque tightening order 1 M 10 screw oiled 45 Nm 2 M 8 screw oiled 20 Nm Measure main bearings front back in the load di rection Enter measured values on record sheet and de termine main bearing play values a See Technical data Measuring axial bearing play Place crankshaft in engine block Insert tensioner rail slide rail pivot pin 1 for centering purposes Tighten housing screws Screw measuring device BMW No 00 2 500 with dial gauge BMW No 00 2 510 into tapped hole for alternator carrier cover Move crankshaft forwards and backwards and read off play at dial gauge a See Technical data RS110320 1 00 2 500 RS110910 00 2 510 11 44 Measuring big end bearing play Measure crankpin with an external micrometer in the thrust direction and offset through 90o Install bearing shells and assemble conrods Using tightening angle gauge
83. ove work instructions in the reverse order 23 1 820 RS230010 23 1 820 23 7 Renewing the shaft sealing rings in the gearbox housing and gearbox cover L Note All shaft sealing rings can be renewed with the gear box installed apart from the input side shaft sealing ring on the input shaft If the gearbox is dismantled completely all shaft sealing rings must be renewed Before installing shaft sealing rings oil their sealing lips lightly Renew the input shaft sealing ring at the input end Lever the shaft sealing ring out with a screw driver Drive the new sealing ring in with the sealing lips facing inwards using slip over sleeve BMW No 23 4 712 and drift BMW No 23 7 711 Renewing output shaft sealing ring e Caution Never use a sharp tool to remove the output shaft sealing ring or the plastic washer on the deep groove ball bearing behind the shaft sealing ring could be damaged Pull the shaft sealing ring out with puller BMW No 00 8 590 Install the sealing ring with the sealing lips facing inwards using slip over sleeve BMW No 23 4 732 and drift BMW No 23 4 731 23 4 712 C330150 23 4 711 00 8 590 23 4 732 23 4 731 23 8 Renewing input shaft sealing ring at output side Pierce the shaft sealing ring with piercing tool BMW No 00 8 583 Screw the pull rod BMW No 00 8 581 into the pierced hole and use impact weight BMW No 00 8 582 to remove the s
84. r else air will be drawn into the clutch operating system If this oc curs repeat the bleeding operation Continue to draw off pump through the brake flu id until it is clear and free from bubbles Close the bleed screw Correct the fluid level Replace the reservoir lid with rubber diaphragm in position Tighten the reservoir cover without using force Operating materials Brake fluid DOT 4 CUB0100 21 8 23 1 Contents Page 23 Technical data 3 Removing and installing gear pedal 5 Removing gearbox 5 Renewing the shaft sealing rings in the gearbox housing and gearbox cover 7 Renew the input shaft sealing ring at the input end 7 Renewing output shaft sealing ring 7 Renewing input shaft sealing ring at output side 8 Renewing shaft sealing ring for selector drum
85. ration Draw off brake fluid until it emerges clear and free from air bubbles Close the bleed screw Installation takes place in the reverse order of re moval X Tightening torque Brake caliper to rear wheel drive 40 Nm Rear wheel to rear wheel drive Initial tightening 50 Nm Final tightening 105 Nm Bleed screw at brake caliper 4 Nm 34 1 500 C000180 C000090 00 24 Additionally with ABS Connect the brake bleeding device to the bleed screw on the pressure modulator for the rear brake arrow this is marked HR Open the bleed screw by half a turn e Caution During brake bleeding make sure that the fluid re plenishing hole is always below the level of the brake fluid or else air will be drawn into the brake system If this occurs repeat the bleeding operation Draw off brake fluid until it emerges clear and free from air bubbles Close the bleed screw If necessary repeat the bleeding procedure Brake fluid grade DOT 4 X Tightening torque Bleed screw at pressure modulator 9 Nm Checking clutch operating fluid level Inspections I II and III e Caution Do not allow brake fluid to come into contact with painted parts of the motorcycle because brake fluid destroys paint Place the
86. sion ring Height mm in 1 170 1 190 0 0461 0 0469 Wear limit mm in 1 1 0 043 Gap clearance mm in 0 2 0 4 0 008 0 016 Wear limit mm in 1 0 0 040 Side clearance mm in 0 030 0 070 0 0012 0 0027 Wear limit mm in 0 15 0 0006 3rd groove Equal chamfer ring tubular spring Height mm in 1 970 1 990 0 0776 0 0783 Wear limit mm in 1 9 0 075 Gap clearance mm in 0 30 0 55 0 012 0 022 Wear limit mm in 1 20 0 047 Side clearance mm in 0 020 0 060 0 0008 0 0024 Wear limit mm in 0 15 0 0006 Installed direction of piston rings Top marking uppermost Piston pin Piston pin dia mm in 21 995 22 000 0 8660 0 8662 Wear limit mm in 21 960 0 8646 Bore dia in piston mm in 22 005 22 011 0 8664 0 8666 Radial clearance in piston mm in 0 005 0 016 0 0002 0 0006 Wear limit mm in 0 070 0 0027 11 11 Sectioned drawing of engine 11 12 Lubricating oil circuit 11 13 Coolant circuit 11 14 11 15 Removing engine L Note Auxiliary shaft timing chains chain tensioner guide rails and crankshaft can only be dismantled after the engine has been removed All other components can be dismantled while the engine is still installed Drain engine oil Drain the brake system completely Drain the clutch operating system completely Attach auxiliary stand BMW No 00 1 550 to the mo
87. tach and pull off Pull the plug connector off the fuel pump assem bly Lift off fuel tank C160010 13 3 010 00 15 Drain fuel tank Remove fuel pump assembly Detach hoses from fuel filter 1 e Caution Note correct direction of flow through fuel filter Use only an O ring seal 2 in good condition After installing check fuel pump assembly for leaks Fit new fuel filter Secure non reusable hose clips with pliers BMW No 13 1 500 X Tightening torque Fuel pump unit 5 Nm Installing L Note Note correct path of vent lines C160020 2 1 00 16 Checking battery acid level topping up if necessary cleaning greasing battery posts Inspections III and IV Release the rubber strap holding the battery Raise the battery and check its acid level Top up battery acid level with distilled water as far as the MAX mark Protective battery post grease e g Bosch Ft 40 V1 Renewing intake air cleaner element Inspection III In very dirty and dusty operating conditions renew every 10 000 km 6 000 miles or even more frequently if necessary Detach and raise the upper part of the air cleaner housing Renew air cleaner element Install the fuel tank Note correct path of vent lines Install the left right trim panels X Tightening torque Fuel tank to rear frame
88. tions 11 Motor 12 Engine electrics 13 Fuel preparation and control 16 Fuel tank and lines 18 Exhaust system 21 Clutch 23 Gearbox 31 Front fork 32 Steering 33 Rear wheel drive Contents Group Chapter 34 Brakes 36 Wheels and tyres 46 Frame 51 Equipment 52 Seat 61 General electrical equipment 62 Instruments 63 Lights Group Chapter 00 1 Contents Page 00 Tightening torques 3 Table of operating fluids 9 Key to maintenance intervals 11 Reading out MoDiTeC fault memory 11 Inspections I II III and IV Checking throttle cable play adjusting if necessary 11 Inspections I and III Changing engine oil renew oil filter element 12 Inspections I II III and IV Changing oil in gearbox 13 Inspections III and IV or at le
89. to rear wheel drive 40 Nm Screw the rear wheel studs in handtight then tighten them in a crosswise pattern Initial tightening 50 Nm Final tightening 105 Nm C000100 C000230 2 1 C000140 00 21 Renewing brake fluid and bleeding brake system Renew the brake fluid annually Inspection IV ABS Inspection II and III Bleeding front brake circuit renewing brake fluid L Note This description applies to brake filling and bleeding devices with vacuum extraction of the brake fluid at the brake caliper If other devices are used comply with their manu facturers instructions Turn the steering to the left e Caution When bleeding the brakes always start on the right side Take off the brake caliper Remove the brake pads Force the pistons fully back with resetting tool BMW No 34 1 500 e Caution Do not allow brake fluid to come into contact with painted parts of the motorcycle because brake fluid destroys paint Take off reservoir cover with rubber diaphragm Release the right handlebar switch Loosen the clamp screw for the handbrake fitting and turn the fitting until the brake fluid reservoir is horizontal e Caution When adding brake fluid do not allow it to enter the holes for the reservoir lid screws Add brake fluid up to the MAX mark arrow Conn
90. torcycle Attach stand BMW No 00 1 520 to motorcycle Remove seat Remove side trim Remove fuel tank Remove the battery e Caution Disconnect negative terminal first then positive ter minal Remove rear wheel Detach the rear brake caliper Detach the ABS sensor Detach the speedometer sensor Remove exhaust manifold Remove silencer muffler Separate oxygen sensor plug Remove line protection from swinging arm Tie the swinging arm up to the rear frame with a strap Remove suspension strut L Note Press the upper suspension strut to the rear Remove rear wheel drive unit Detach brake hose holder at rear frame Press off the left swinging arm bearing cap e Caution When installing make sure the O ring is in good condition Install with the drain hole pointing down Loosen the left swinging arm bearing Loosen the screws at the right swinging arm bearing Use pull rod BMW No 00 8 581 and impact weight BMW No 00 8 582 to pull out the swinging arm bearing Remove the left swinging arm bearing C360011 00 1 550 C110010 00 1 520 C330030 C330040 00 8 582 00 8 581 11 16 Remove rear swinging fork Press off drive shaft Remove the air intake stub pipe Remove brake fluid reservoir from holder Remove the holder Take off the right plug retaining plate Pull the air
91. unt cover Place sliding sleeve BMW No 11 5 680 on crankshaft Apply 3 Bond 1209 to the sealing face arrow which must be clean and free from grease Install alternator mount cover X Tightening torque M 8 screw 20 Nm M 6 screw 9 Nm Installing magnetic gate belt pulley Install Hall effect trigger plate 1 Lock clutch housing with special tool BMW No 11 5 640 Secure rotor 2 of Hall effect gate to the Poly V belt pulley 3 with for example Loctite instant adhesive Install the Poly V belt pulley e Caution Install retainer for Hall effect gate rotor 4 at groove in crankshaft 5 X Tightening torque Retaining screw for belt pulley 50 Nm Install rotary breather pipe 6 with new sealing rings X Tightening torque Vent line to alternator mount cover M 8 screw 20 Nm Banjo screw 25 Nm 11 5 680 RS110450 11 5 640 6 3 2 1 4 5 u 11 61 Timing the ignition Using TDC locating pin BMW No 11 2 650 lock the clutch housing Connect BMW MoDiTeC with adapter cable to Hall effect gate plate Adjust in accordance with tester guidance Remove the TDC locating pin 11 2 650 RS110461 11 62 Installing alternator
92. usting value Initial throttle cable play setting engine cold 1 5 mm 0 06 in Throttle cable play engine warm 0 5 mm 0 02 in C000010 00 12 Changing engine oil renew oil filter element Inspections I II III and IV L Note If the motorcycle is ridden only for short distances or outside temperatures are below 0 C 32 F change the oil and renew the oil filter element every 3 months but at least every 3 000 km 1 800 miles Change the oil while it is at regular operating temperature Remove screw plug Unscrew oil drain plug and drain off oil Fit new seal and screw in drain plug Use oil filter wrench BMW No 11 4 650 to un screw and remove the oil filter Coat sealing ring on new oil filter element with oil and screw in Add oil Insert and tighten the screw plug Check engine oil level with the motorcycle in a horizontal position use the auxiliary stand BMW No 00 1 550 e Caution Never add engine oil above the MAX mark X Tightening torque Oil filter 11 Nm Oil drain plug 32 Nm Fill quantity for engine With oil filter change 3 75 l 6 6 Imp pints 3 96 US quarts Without oil filter change 3 50 l 6 2 Imp pints 3 69 US quarts Oil volume between MIN and MAX marks 0 50 l 0 88 Imp pint 0 52 US quart Engin
93. valve stem seal with pliers BMW No 11 1 250 L Note If a valve is removed the valve stem seal must be re newed RS110130 11 5 690 11 1 250 11 27 Checking valves for wear Clean combustion residue from valves Check valve dimensions a See Technical data Remachining valve seat e Caution Width B and diameter D must always be main tained when remachining the valve seat a See Technical data Checking and repairing cylinder head Remove combustion residues from combusion chamber Check sealing face for damage distortion and skim flat if necessary Skimming sealing face max 0 2 mm 0 008 in metal removal Checking valve guide for wear Check valve guide bore a See Technical data RS110890 B D 11 28 Replacing valve guides Heat cylinder head slowly and uniformly to 200 C 392 F in a suitable oven e Caution Wear protective gloves when handling heated parts Drive out valve guides with 5 mm 0 20 in dia ex tractor pin BMW No 11 5 674 from the com bustion chamber side Allow cylinder head to cool down to room tem perature app 20 C 68 F Examine valve guide bore for wear widening taper and correct dimensions in H7 tolerance range 12 500 12 518 mm 0 4921 0 4928 in L
94. while at regular operating temperature e Caution Note that the interior of the gearbox is slightly pres surised Slacken off oil drain plug 4 so that the pressure drops Unscrew and remove oil filler plug 5 Unscrew and remove oil drain plug 4 and allow the oil to drain out Fit new seal and screw in drain plug Add gearbox oil Insert oil filler plug with new seal Release the fastening pull out inductive signal transmitter 6 and clean it X Tightening torque Oil drain plug 23 Nm Oil filler plug 23 Nm Fill quantity Initial filling up to lower edge of filler hole app 0 20 l 0 35 Imp pint 0 21 US quart Oil change up to lower edge of filler hole app 0 20 l 0 35 Imp pint 0 21 US quart Oil grade for rear wheel drive Brand name hypoid gear oil SAE 90 API class GL 5 C000040 1 2 3 C000050 5 6 4 00 14 Renewing fuel filter Inspection III In normal operating conditions every 40 000 km 24 000 miles if fuel quality is poor every 20 000 km 12 000 miles Remove seat Remove right air cleaner trim panel Remove left and right trim panels e Caution Fuel is flammable and a hazard to health Observe relevant safety regulations Take off the fuel tank Seal the fuel feed and return lines with a hose clip BMW No 13 3 010 de

BMW R 1200 CL Repair manual

Contents

Download Pdf Manuals

Related Search

Related Contents