BMW R 850 C, R 1200 C - Workshop Manual / Repair Manual

BMW R 850 C, R 1200 C - SERVICE MANUAL

Workshop Manual, to motorcycles BMW R 850 C &R 1200 C


INDEX:
    

INTRODUCTION
MAINTENANCE SCHEDULE
PRE-DELIVERY CHECK
00 MAINTENANCE AND GENERAL INSTRUCTIONS
Tightening torques
Table of operating fluids
Key to maintenance intervals
Reading out MoDiTeC fault memory
(Inspections I, II, III and IV)
Checking throttle cable play, adjusting if necessa...
(Inspections I and III)
Changing engine oil, renew oil filter element
(Inspections I, II, III and IV)
Changing oil in gearbox
(Inspections III and IV)
or at least every 2 years
Changing oil in rear wheel drive; cleaning inducti...
(Inspections I, III and IV)
Every 40 000 km (24 000 miles) or at least every 2...
Renewing fuel filter
(Inspection III)
In normal operating conditions every 40 000 km (24...
Checking battery acid level/topping up if necessar...
(Inspections III and IV)
Renewing intake air cleaner element
(Inspection III)
In very dirty and dusty operating conditions, rene...
Renewing Poly-V belt
(every 60 000 km/36 000 miles)
(Inspection III)
Poly-V belt adjusting procedure:
Checking brake fluid level
Front brake
Rear brake
Checking brake pads and discs for wear/renewing
(Inspections II and III)
Checking front brake pad wear
Checking rear brake pad wear
Checking brake disc wear
Renewing brake pads Front brake
Renewing brake pads Rear brake
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
Additionally with [ABS]
Bleeding rear brake circuit/renewing brake fluid
Additionally with [ABS]
Checking clutch operating fluid level
(Inspections I, II and III)
Checking tightness of rear wheel studs
(Inspection I)
Checking rear wheel bearing play by tilting wheel
(Inspection III)
Checking swinging arm bearings, adjusting if neces...
(Inspections I and III)
Greasing the side (prop) stand pivot
(Inspections I, II and III)
Checking function of side (prop) stand contact swi...
(Inspections I, II, III and IV)
Tightening cylinder heads
(Inspection I)
Checking/adjusting valve operating clearances
(Inspections I, II and III)
Checking/renewing spark plugs
(Inspection II)/renewing (Inspection III)
Check synchronising
(Inspections I, II and III)
Final inspection with road safety and functional c...
(Inspections I, II, III and IV)
Road safety check
Roadworthiness check
11 MOTOR
Sectioned drawing of engine
Lubricating oil circuit
Coolant circuit
Removing engine
Dismantling engine
Removing cylinder head cover
Locking the engine in the TDC position
Top dead centre on ignition stroke:
Removing and installing chain tensioner
Assembly specification for timing chain tensioner:...
Removing valve gear holder
Dismantling/reassembling valve gear holder
Removing cylinder head
Dismantling, checking, repairing and re-assembling...
Removing and installing valves
Removing valve stem seals
Checking valves for wear
Remachining valve seat
Checking and repairing cylinder head
Checking valve guide for wear
Replacing valve guides
Installing valve and valve stem seal
Removing cylinder barrel
Removing/dismantling piston
Checking pistons and cylinders
Assembling pistons
Removing/installing conrod
Removing and installing alternator cover with engi...
Removing alternator mount cover
Renewing radial shaft seal in alternator mount cov...
Renewing radial shaft seal for rotary breather
Removing auxiliary shaft drive
Removing oil pump
Removing radial shaft seal on crankshaft with engi...
Dismantling crankcase
Removing crankshaft, auxiliary shaft and timing ch...
Removing and installing oil pick-up basket
Replacing oil level sight glass
Removing conrods
Checking conrods
Measuring main and big end bearing play
Measuring radial bearing play
Installing main bearing
Measuring axial bearing play
Measuring big end bearing play
Assembling engine
Installing conrod
Installing crankshaft
Installing timing chain tensioning and slide rails...
Installing auxiliary shaft/timing chains
Assembling engine block
Installing the crankshaft radial seal
Installing clutch housing
Installing oil pump
Installing auxiliary shaft drive
Installing piston
Installing cylinder
Installing cylinder head
Adjusting valve clearances
Installing right cylinder head
Adjustment specification
Installing left cylinder head
Adjustment specification
Installing alternator mount cover
Installing magnetic gate/belt pulley
Timing the ignition
Installing alternator
Installing engine
12 ENGINE ELECTRICS
Removing and installing coil and ignition lead
Check ignition coil resistance
Removing and installing alternator
Poly-V belt adjusting procedure:
Dismantling/reassembling alternator
Checking alternator
Checking armature for short to ground (earth)
Removing and installing starter motor
Dismantling/reassembling starter motor
Renewing carbon brushes
Checking starter motor
Checking starter relay
Removing and installing magnetic gate
Timing the ignition
13 FUEL PREPARATION AND CONTROL
Removing and installing air cleaner
Removing and installing throttle stub pipe
Removing and installing throttle potentiometer
Removing and installing throttle positioner
Removing and installing throttle potentiometer
Removing and installing injectors
Removing and installing Motronic control unit
16 FUEL TANK AND LINES
Removing and installing fuel tank
Removing and installing fuel filter, fuel pump and...
Removing and installing fuel filter
Removing and installing fuel pump and fuel level s...
Checking fuel pump pressure
Removing and installing fuel distributor and press...
18 EXHAUST SYSTEM
Removing and installing exhaust system
Removing and installing silencer (muffler)
Removing and installing front exhaust pipes
21 CLUTCH
Removing and installing clutch hydraulic line
Removing and installing clutch slave cylinder
Filling/bleeding clutch line
Removing and installing clutch
Removing clutch
Installing clutch
23 GEARBOX
Removing and installing gear pedal
Removing gearbox
Renewing the shaft sealing rings in the gearbox ho...
Renew the input shaft sealing ring at the input en...
Renewing output shaft sealing ring
Renewing input shaft sealing ring at output side
Renewing shaft sealing ring for selector drum
Renewing sealing ring for selector shaft
Dismantling gearbox
Removing gearbox housing
Removing selector drum
Dismantling/assembling selector shaft
Removing gearbox shafts
Renewing deep-groove ball bearing on intermediate ...
Dismantling/assembling input shaft
Dismantling input shaft
Assembling input shaft
Dismantling/reassembling output shaft
Stripping down output shaft
Assembling output shaft
Checking endplay
Checking/adjusting fully compressed length of gear...
Checking/adjusting fully-compressed length of inte...
Checking/adjusting fully-compressed length of outp...
Checking/adjusting fully-compressed length of inpu...
Checking/adjusting fully-compressed length of sele...
Shimming selector shaft
Assembling gearbox
Installing input, output and intermediate shaft
Installing selector shaft
Installing selector drum
Assembling gearbox housing
31 FRONT FORK
Removing and installing telescopic fork
Removing and installing telescopic fork
Removing and installing fork bridge
Removing and installing pot-type joints
Removing and installing ball thrust bearing
Removing and installing slider tube bridge
Removing and installing ball joint
Checking friction at ball joint/ball thrust bearin...
Assembly specification for telescopic fork:
Dismantling/reassembling telescopic fork
Dismantling telescopic fork
Assembling telescopic fork
Measuring telescopic fork
Check slider tube bridge
Checking runout of fixed tube
Removing and installing leading link
Dismantling/reassembling leading link
Removing and installing front suspension strut
32 STEERING
Removing and installing left handlebar fitting
Removing and installing right handlebar fitting
Removing and installing handlebar
Removing/installing throttle cable
33 REAR WHEEL DRIVE
Removing, dismantling, reassembling and installing...
Removing rear wheel drive
Removing input bevel pinion
Disassembling input bevel pinion
Removing needle roller bearing for input bevel pin...
Installing needle roller bearing for input bevel p...
Assembling input bevel pinion
Installing input bevel pinion
Removing and dismantling the crown wheel
Assembling/installing crown wheel
Checking/adjusting backlash
Checking tooth contact pattern
Shimming housing cover
Installing housing cover
Installing splined element
Removing/installing rear swinging fork
Removing rear swinging arm
Removing and installing taper roller bearing
Removing and installing flexible gaiter
Removing drive shaft
Checking universal joint for wear
Installing drive shaft
Installing rear swinging arm
Installing rear wheel drive
Removing and installing suspension strut
34 BRAKES
Removing and installing front brake caliper
Dismantling and assembling front brake caliper
Dismantling front brake caliper
Assembling front brake caliper
Removing and installing rear brake caliper
Dismantling and assembling rear brake caliper
Dismantling rear brake caliper
Assembling rear brake caliper
Removing and installing front brake disc
Removing/installing rear brake disc
Removing and installing front ABS sensor
Adjusting front ABS sensor gap
Marking sensor wheel
Checking and adjusting sensor gap
Removing and installing rear ABS sensor
Adjusting rear ABS sensor gap
Marking sensor wheel
Checking and adjusting sensor gap
Removing and installing rear brake master cylinder...
Checking and adjusting relief clearance of piston ...
Removing and installing brake pedal
Removing and installing ABS unit
Removing the ABS unit
Installing the ABS unit
Removing and installing ABS relay and relay base
Removing ABS relay
Installing the ABS relay
Removing ABS relay base
Installing the ABS relay base
Removing and installing brake lines
Removing and installing front brake line
Removing and installing rear brake line
36 WHEELS AND TYRES
Removing and installing front wheel
Removing front wheel
Installing front wheel
Removing and installing wheel bearings
Removing/installing rear wheel
Static balancing of front wheel/rear wheel
Checking front/rear wheel rim for runout
Removing/installing spokes
Centering the wheel rim
Centering lateral runout
46 FRAME
Removing and installing rear mudguard
Removing/installing front mudguard
Removing and installing front frame
Removing and installing rear frame
Removing/installing footrest supports
Removing and installing side (prop) stand
Checking running gear
Measuring wheel track offset

51 EQUIPMENT
Removing and installing ignition switch/steering l...
Removing and installing ignition/light switch
Removing and installing lock barrel
Drilling out lock barrel
Removing and installing lock barrel for fuel tank ...
Drilling out lock barrel
52 SEAT
Removing and installing seat
61 GENERAL ELECTRICAL EQUIPMENT
Removing and installing central electrical equipme...
Relay positions (central electrical equipment box)...
Connections to fuses:
Frame wiring harness
Wiring harness View from left
Wiring harness View from right
62 INSTRUMENTS
Removing and installing instrument cluster
Dismantling and assembling instrument cluster
63 LIGHTS
Removing and installing headlight
Adjusting headlight