BMW R 1200 C Repair Manual
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BMW R 1200 C Repair Manual

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Repair Manual
R 850 C
R 1200 C
BMW AG Motorcycle Division
After Sales

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  • Page 1 Repair Manual R 850 C R 1200 C BMW AG Motorcycle Division After Sales...
  • Page 2 Published by: © BMW AG Motorcycle Division After Sales UX-VS-2 All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission. Errors and omissions excepted; subject to technical amendment. Printed in Germany 3/99...
  • Page 3 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.
  • Page 5 BMW AG Motorcycle Division Maintenance schedule R 1100 S / R 850/1200 C / R 1150 GS Customer Licence plate No. Order No. Mechanic’s signature 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...
  • Page 6 BMW AG Motorcycle Division Pre-delivery check R 1100 S / R 850/1200 C / R 1150 GS Customer Licence plate No. Pre-delivery check Order No. Mechanic’s signature Check the shipping crate for damage Motorcycle: – unpack – install remaining items –...
  • Page 7 Contents Group / Chapter 00 Maintenance and general instructions 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...
  • Page 8 Group / Chapter 34 Brakes 36 Wheels and tyres 46 Frame 51 Equipment 52 Seat 61 General electrical equipment 62 Instruments 63 Lights...

  • Page 9: Table Of Contents

    00 Maintenance and general instructions Contents Page 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...
  • Page 10 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...

  • Page 11: Tightening Torques

    Tightening torques Model R 850/1200 C Connection 11 Engine Cylinder head Tightening sequence: 1. Tighten cylinder head nuts (oiled) crosswise 1.1 Tighten all nuts to correct torque for joint 1.2 Tighten all nuts to correct angle 90° 1.3 Tighten all nuts to correct angle 90°...
  • Page 12 Model R 850/1200 C Connection 11 Engine Oil filter Oil filter Oil drain plug Oil pump Mesh filter basket to engine block Oil pump cover Pressure relief valve Oil pressure switch Oil cooler Oil cooler pipe to engine block Cooling oil line - banjo screw with oil vent valve Oil cooler to frame Oil cooler return line to engine block Screw-in union for oil cooler connection at engine...
  • Page 13 Model R 850/1200 C Connection 12 Engine electrics Starter motor to engine Starter cover to housing Positive lead to starter motor Alternator to cover mount Tensioning and retaining strap at alternator Spacer at alternator Positive lead to alternator Belt pulley at alternator Belt pulley to crankshaft Poly-V belt preload Spark plug...
  • Page 14 Model R 850/1200 C Connection 23 Transmission Oil filler plug Oil drain plug Gearbox to engine block Gear shift pedal to rear frame Selector lever to selector shaft Gearbox cover to gearbox housing 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)
  • Page 15 Model R 850/1200 C Connection 34 Brakes Brake caliper at fork slider tube Brake caliper to rear wheel drive 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 Brake pedal to footrest assembly Brake lines/brake hose to brake...
  • Page 16 Model R 850/1200 C Connection 46 Frame Frame to engine M12 pin M10 screw Rear frame to engine to gearbox Side (prop) stand pivot mount to engine Side (prop) stand to pivot mount 42 (clean thread + Loctite 243) Footrest assembly to engine M12 screw M8 screw Pillion footrest holder to rear frame...

  • Page 17: Table Of Operating Fluids

    Table of operating fluids Item 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 Wheel, steering head and taper roller...
  • Page 18 00.10...

  • Page 19: Key To Maintenance Intervals

    BMW Service • – BMW Inspection Check throttle cable for free movement and free- – BMW Annual Service dom from abrasion or kinking; renew if neces- sary. • With the steering turned to various angles, open Reading out MoDiTeC fault memory the throttle twistgrip fully and allow it to close again.

  • Page 20: Changing Engine Oil, Renew Oil Filter Element

    Change the oil while it is at regular operating temperature. 11 4 650 C000030 • 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.

  • Page 21: Changing Oil In Gearbox

    Changing oil in gearbox Changing oil in rear wheel drive; cleaning inductive signal transmitter at rear wheel (Inspections III and IV) or at least every 2 years (Inspections I, III and IV) Every 40 000 km (24 000 miles) or at least every •...

  • Page 22: Renewing Fuel Filter

    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, detach and pull off. 00.14...
  • Page 23 Use only an O-ring seal (2) in good condition. Note: After installing, check fuel pump assembly for leaks. Note correct path of vent lines. • Fit new fuel filter. • Secure non-reusable hose clips with pliers, BMW No. 13 1 500. 00.15...

  • Page 24: Checking Battery Acid Level/Topping Up If Necessary, Cleaning/Greasing Battery Posts

    C000020 Checking battery acid level/topping Renewing intake air cleaner up if necessary, cleaning/greasing element battery posts (Inspection III) (Inspections III and IV) In very dirty and dusty operating conditions, renew every 10 000 km (6 000 miles) or even • Release the rubber strap holding the battery.

  • Page 25: Renewing Poly-V Belt

    • Use spark plug wrench, BMW No. 12 3 510, to unscrew and remove the spark plugs. Poly-V belt tensioning procedure: 1. Screw hex nut (1) on adjusting screw (2) up handtight (no tools to be used) 2.

  • Page 26: Checking Brake Fluid Level

    Checking brake system for correct Rear brake operation and freedom from leaks; • Position the motorcycle horizontally with auxiliary repairing/renewing if necessary stand, BMW No. 00 1 550. • (Inspection III) Brake fluid must not drop below the minimum level (arrow). •...

  • Page 27: Checking Brake Pads And Discs For Wear/Renewing

    Checking brake pads and discs for Checking rear brake pad wear wear/renewing (Inspections II and III) Checking front brake pad wear C000120 It should not be possible to see the brake disc through the hole (arrow) in the inner brake pad. C000100 If the brake disc is visible, the wear limit has been reached and the pads must be renewed.

  • Page 28: Renewing Brake Pads Front Brake

    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. Tightening torque: Brake caliper at fork slider tube....40 Nm 00.20...

  • Page 29: Renewing Brake Fluid And Bleeding Brake System

    C000150 the components with great care. • Force the pistons fully back with resetting tool, BMW No. 34 1 500. Next check brake fluid level with the motorcy- Caution: cle on its side (prop) stand and the handlebar turned Do not allow brake fluid to come into contact with...

  • Page 30: Additionally With [Abs]

    Connect the brake bleeding device to the pres- Take out the resetting tool and insert spacer, sure modulator for the front brake (arrow); this is BMW No. 34 1 520, in its place. • marked VR. Press the pistons back in the second brake cali- •...

  • Page 31: Bleeding Rear Brake Circuit/Renewing Brake Fluid

    Take off the reservoir cover. 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.

  • Page 32: Additionally With [Abs]

    Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint. • Place the motorcycle on the auxiliary stand, BMW No. 00 1 550. • Turn the steering to the right. C000190 •...

  • Page 33: Checking Tightness Of Rear Wheel Studs

    (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.

  • Page 34: Tightening Cylinder Heads

    Tightening cylinder heads Checking/adjusting valve operating clearances (Inspection I) (Inspections I, II and III) C000210l RS110980 • Remove cylinder head cover. • Check valve clearance with feeler gauge and, if Caution: necessary, correct with adjusting nut/lock. Trap escaping oil. Adjust valve clearances with the engine cold (max.

  • Page 35: Checking/Renewing Spark Plugs

    12 3 510 C000060 C000220 • Unscrew and remove spark plugs with the spark plug wrench, BMW No. 12 3 510. • Connect the BMW Synchrotester hose to the vacuum stub pipe (arrow) and the lines to the Caution: MoDiTeC.

  • Page 36: Final Inspection With Road Safety And Functional Check

    Final inspection with 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 ........
  • Page 37 11 Motor Contents Page Technical data ..........................5 Sectioned drawing of engine ....................11 Lubricating oil circuit .......................12 Coolant circuit ..........................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...
  • Page 38 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...
  • Page 39 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 11.3...
  • Page 40 11.4...

  • Page 41: Technical Data

    Technical data R 850 C R 1200 C Engine, general Engine design Four-stroke flat twin, air-cooled 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...
  • Page 42 Technical data R 850 C R 1200 C Valves Included angle between valves ° 41 Valve clearances with engine cold 0.15 (0.006) (max. 35 °C/95 °F) 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°...
  • Page 43 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.
  • Page 44 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) 25.020...25.041 (0.9851...0.9859) Auxiliary shaft dia.
  • Page 45 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...
  • Page 46 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...

  • Page 47: Sectioned Drawing Of Engine

    Sectioned drawing of engine 11.11...

  • Page 48: Lubricating Oil Circuit

    Lubricating oil circuit 11.12...

  • Page 49: Coolant Circuit

    Coolant circuit 11.13...
  • Page 50 11.14...

  • Page 51: Removing Engine

    Press off the left swinging arm bearing cap. Caution: C360011 When installing, make sure the O-ring is in good condition. • Attach auxiliary stand, BMW No. 00 1 550, to the Install with the drain hole pointing down. motorcycle. • Loosen the left swinging arm bearing. •...
  • Page 52 • 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.
  • Page 53 • 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. Caution: Do not scratch the surface of the leading link.

  • Page 54: Dismantling Engine

    00 0 630 RS110010 Dismantling engine • Attach engine mount, BMW No. 11 0 630, to the engine block. • Transfer engine to assembly frame. 11 4 650 RS110950 • Drain engine oil. • Remove the oil filter, using oil filter wrench, BMW No.

  • Page 55: Removing Cylinder Head Cover

    12 3 510 RS110020 Removing cylinder head cover • Unscrew and remove spark plug with the spark plug wrench, BMW No. 12 3 510. • Remove cylinder head cover. Caution: Trap escaping oil. 11.19...

  • Page 56: Locking The Engine In The Tdc Position

    Prevent the clutch housing from moving with locking device, BMW No. 11 5 640. RS110461 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. 11.20...

  • Page 57: Removing And Installing Chain Tensioner

    RS110060 Removing and installing chain tensioner Caution: Do not accidentally confuse the chain tensioner pis- tons. When installing, fit a new gasket. Assembly specification for timing chain ten- sioner: Removal: • Remove timing chain tensioner, then remove camshaft sprocket from camshaft. Installing: •...

  • Page 58: Removing Valve Gear Holder

    M6 x 60 M6 x 30 M6 x 30 M6 x 30 RS110070 Removing valve gear holder • Remove valve gear holder. • Secure rockers with a rubber band (2). Note: If no work is carried out on the valve gear holder, re- move it together with the cylinder head.

  • Page 59: Dismantling/Reassembling Valve Gear Holder

    RS110080 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. Caution: Do not accidentally confuse rocker shafts and push- rods.
  • Page 60 RS110090 • Remove camshaft bearing cap (1). • Remove camshaft and bearings (2). • Remove bucket-type tappets. Caution: Do not accidentally confuse the bucket-type tap- pets. • Reassemble in the reverse order of work. Caution: Note direction of installation (3) for camshaft bearing cap.

  • Page 61: Removing Cylinder Head

    M10 x 70 M6 x 30 M6 x 30 M6 x 30 RS110110 Removing cylinder head 11.25...

  • Page 62: Dismantling, Checking, Repairing And Re-Assembling Cylinder Head

    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.

  • Page 63: Checking Valves For Wear

    Checking valves for wear • Clean combustion residue from valves. • Check valve dimensions..........See Technical data Remachining valve seat RS110890 Caution: Width (B) and diameter (D) must always be main- tained when remachining the valve seat..........See Technical data Checking and repairing cylinder head •...

  • Page 64: Replacing Valve Guides

    • Drive out valve guides with 5 mm (0.20 in) dia. ex- must be –40 °C (–40 °F). tractor pin, BMW No. 11 5 674, from the com- • bustion chamber side. Place heated cylinder head flat on workbench or •...

  • Page 65: Installing Valve And Valve Stem Seal

    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. Caution: Remove the shrunk-on tube. •...

  • Page 66: Removing Cylinder Barrel

    RS110170 Removing cylinder barrel • Unscrew and remove guide rail bearing screw (1). • Unscrew and remove cylinder retaining screws, and remove cylinder. Caution: When removing cylinder, ensure that the piston does not strike the engine block. Removing/dismantling piston • Remove both retaining rings on piston pin.

  • Page 67: Checking Pistons And Cylinders

    Checking pistons and cylinders Assembling pistons Reference temperature for measurements: ..20 °C (68 °F) R 850 1. 2. RS110190 RS110180 • Carefully fit piston rings to piston in the following • Measure cylinder bore with internal probe at sequence, using piston ring pliers: 20 mm (0.79 in) and 100 mm (3.94 in) from the 3rd groove - equal chamfer ring top in direction of piston pin, and again at a right...

  • Page 68: Removing/Installing Conrod

    Turn crankshaft to TDC position. Caution: • Lock the clutch housing with special tool Oil the bearings. BMW No. 11 5 640. • • Remove conrod. Screw the big end bolts in by hand, then tighten them with a tightening angle indicator, Note: BMW No.

  • Page 69: Removing And Installing Alternator Cover With Engine Installed

    • 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). Note: If complete alternator mount cover is removed, leave magnetic gate (3) installed.

  • Page 70: Renewing Radial Shaft Seal In Alternator Mount Cover

    • 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. 11.34...

  • Page 71: Removing Auxiliary Shaft Drive

    Remove chain tensioning rail (3). • Remove chain guide rail (4). • Lock clutch housing with special tool BMW No. 11 5 640. • Unscrew and remove chain sprocket retaining bolt (5). • Remove rotor (6) with chain sprocket (7) and tim- ing chain (8).

  • Page 72: Removing Oil Pump

    M6 x 45 M6 x 50 M6 x 45 M6 x 45 RS110410 M6 x 50 Removing oil pump • Remove oil pump cover (1). • Remove complete oil pump (2) together with cooling oil pipe (3), and dismantle. Caution: Check installed positions of parts which have al- ready been run together.

  • Page 73: Removing Radial Shaft Seal On Crankshaft With Engine Installed

    11 5 640 C210010 Removing radial shaft seal on crankshaft with engine installed • Lock clutch housing with special tool BMW No. 11 5 640. • Remove the clutch. RS110270 • Carefully lever radial shaft seal out, using a screwdriver.

  • Page 74: Dismantling Crankcase

    RS110261 Dismantling crankcase • Turn engine on to its side. • Remove screws on right side. 11.38...
  • Page 75 RS110260 • Turn engine on to its side. • Remove screws on left side. • Remove upper section of crankcase. 11.39...

  • Page 76: Removing Crankshaft, Auxiliary Shaft And Timing Chain Tensioning And Slide Rails

    RS110290 Removing crankshaft, auxiliary shaft and timing chain tensioning and slide rails 11.40...

  • Page 77: Removing And Installing Oil Pick-Up Basket

    • 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.

  • Page 78: Measuring Main And Big End Bearing Play

    RS110310 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..........See Technical data Caution: The crankshaft can only be reground in grinding stage 0;...

  • Page 79: Installing Main Bearing

    00 2 510 RS110910 • 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.

  • Page 80: Measuring Big End Bearing Play

    ..........See Technical data • Install bearing shells and assemble conrods. • Using tightening angle gauge, BMW No. 11 2 210, tighten the big end bolt. Tightening torque: Big end bolts oiled Joint torque..........20 Nm Wrench angle ............ 80° 11.44...

  • Page 81: Assembling Engine

    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. Caution: Oil the bearings. Do not accidentally confuse conrods or bearing shells.

  • Page 82: Installing Crankshaft

    RS110291 Installing crankshaft Installing auxiliary shaft/timing chains Caution: Caution: Oil the bearings. Timing chains (2) must mesh fully with auxiliary shaft sprockets. 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.

  • Page 83: Assembling Engine Block

    RS110920 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. 11.47...
  • Page 84 RS110391 • Bolt the crankcase sections together. Tightening torque/tightening order: 1. M10 screw (oiled) ........45 Nm 2. M 8 screw (oiled) ........20 Nm 3. M 6 screw ..........9 Nm 11.48...

  • Page 85: Installing The Crankshaft Radial Seal

    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). 11.49...

  • Page 86: Installing Clutch Housing

    • 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. Tightening torque: Clutch housing to crankshaft (screw threads oiled) ....40 Nm Additional wrench angle ........

  • Page 87: Installing Oil Pump

    M6 x 45 M6 x 50 M6 x 45 M6 x 45 M6 x 50 RS110411 Installing oil pump 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). Caution: O-ring (3) must be in good condition.

  • Page 88: Installing Auxiliary Shaft Drive

    M 6 screw ............ 10 Nm Banjo screw for cooling oil line with oil vent valve ......... 25 Nm • Lock the clutch housing with special tool BMW No. 11 5 640. • Install chain sprocket (1). Tightening torque: M 6 screw ............ 10 Nm •...

  • Page 89: Installing Piston

    RS110430 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. Caution: Ensure that retaining rings are properly seated on piston pin.

  • Page 90: Installing Cylinder

    • 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.

  • Page 91: Installing Cylinder Head

    • • Install cylinder head gasket. Lock clutch housing with special tool • Fit cylinder head/insert correctly positioned cam- BMW No. 11 5 640. • shaft chain sprocket (1) and timing chain into Tighten camshaft chain sprocket. chain cavity. •...

  • Page 92: Adjusting Valve Clearances

    RS110980 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 engine cold (max. 35 °C/95 °F): Inlet ...........

  • Page 93: Installing Right Cylinder Head

    RS110150 • Locate ignition-stroke TDC with insert pin, BMW No. 11 2 650, at hole in clutch housing and engine block. Note: With the engine installed, adjust TDC with dial gauge holder, BMW No. 00 2 650, and dial gauge, BMW No.

  • Page 94: Installing Left Cylinder Head

    RS110511 • Locate ignition-stroke TDC with insert pin, BMW No. 11 2 650, at hole in clutch housing and engine block. Note: With engine installed, adjust to TDC with dial gauge holder, BMW No. 00 2 650, and dial gauge, BMW No.
  • Page 95 RS110050 RS110940 • • Install the end cover with an O-ring which is in Install cylinder head cover. good condition. Caution: Tightening torque: Ensure that gaskets are properly seated. Gaskets M 6 screw ............9 Nm and sealing face must be free from oil and grease. Tightening torque: Cover screw...........

  • Page 96: Installing Alternator Mount Cover

    Installing alternator mount cover • Install rotary breather pipe (6) with new sealing rings. • Place sliding sleeve, BMW No. 11 5 680, on crankshaft. Tightening torque: • Apply 3-Bond 1209 to the sealing face (arrow), Vent line to alternator mount cover which must be clean and free from grease.

  • Page 97: Timing The Ignition

    11 2 650 RS110461 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. •...

  • Page 98: Installing Alternator

    RS110480 Installing alternator • 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.

  • Page 99: Installing Engine

    Tightening torque: Oil filter (sealing face lightly oiled) ....11 Nm Oil drain plug..........32 Nm 12 3 510 RS000010 • Install spark plugs with spark plug socket wrench, BMW No. 12 3 510. Tightening torque: Spark plug............ 20 Nm 11.63...
  • Page 100 11.64...
  • Page 101 12 Engine electrics Contents Page Technical data ..........................3 Removing and installing coil and ignition lead ............5 Check ignition coil resistance ....................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...
  • Page 102 12.2...

  • Page 103: Technical Data

    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...
  • Page 104 12.4...

  • Page 105: Removing And Installing Coil And Ignition Lead

    Caution: Switch off ignition. Disconnect ground (earth) cable at battery and insulate 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.

  • Page 106: Removing And Installing Alternator

    RS110480 Removing and installing alternator • Place sliding sleeve, BMW No. 11 5 680, on the crankshaft and remove the alternator support cover. • • Remove seat. Detach the central electrical equipment box and • Remove fuel tank. raise it as far as possible.

  • Page 107: Dismantling/Reassembling Alternator

    RS120050 Dismantling/reassembling Checking alternator alternator • Test with BMW MoDiTeC. • Take out the cover retaining screws (1). Checking armature for short to ground • Release clips (2) and remove the cover. (earth) • Remove voltage regulator (3). • Remove the Poly-V belt pulley.

  • Page 108: Removing And Installing Starter Motor

    C120020 Removing and installing starter motor 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. •...

  • Page 109: Dismantling/Reassembling Starter Motor

    RS120080 Dismantling/reassembling starter Checking starter motor motor • Test with MoDiTeC. • Detach lead (1). Checking starter relay • Remove retaining screws (2). • • Remove flange (3). Test with MoDiTeC. • Remove solenoid switch (4) after taking out the retaining screws (5).

  • Page 110: Removing And Installing Magnetic Gate

    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.

  • Page 111: Timing The Ignition

    00 2 650 C120040 • 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.
  • Page 112 12.12...

  • Page 113: Fuel Preparation And Control

    13 Fuel preparation and control Contents Page 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 ..............6 Removing and installing throttle potentiometer ............6 Removing and installing injectors ..................6...
  • Page 114 13.2...

  • Page 115: Technical Data

    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 13.3...
  • Page 116 13.4...

  • Page 117: Removing And Installing Air Cleaner

    See Group 46 (Removing/installing rear frame) • 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. 13.5...

  • Page 118: Removing And Installing Throttle Positioner

    When a new throttle potentiometer is installed, it and pull off the plug. • must be adjusted in accordance with the Unfasten retainer (2) for fuel pipe and pull off the BMW MoDiTeC reading. pipe. • Remove injector. • Install by following the above work instructions in the reverse order.

  • Page 119: Removing And Installing Motronic Control Unit

    Removing and installing Motronic control unit • Remove fuel tank. Caution: Switch off ignition; disconnect earth (ground) lead at battery and insulate it. C130030 • Remove Motronic control unit. • Remove connector strip. • Install by following the above work instructions in the reverse order.
  • Page 120 13.8...

  • Page 121: Fuel Tank And Lines

    16 Fuel tank and lines Contents Page Technical data ..........................3 Removing and installing fuel tank ..................5 Removing and installing fuel filter, fuel pump and fuel level 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...
  • Page 122 16.2...

  • Page 123: Technical Data

    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 Operating voltage V 12 Fuel pressure bar (psi) 3±0.2 (42.69±2.85) Delivery volume l/h (Imp.gal/h,...
  • Page 124 16.4...

  • Page 125: Removing And Installing Fuel Tank

    13 3 010 C160010 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. Tightening torque: Fuel tank to rear frame ......... 22 Nm 16.5...

  • Page 126: Removing And Installing Fuel Filter, Fuel Pump And Fuel Level Sensor

    Note direction of fuel flow at filter. Fuel is flammable and a hazard to health. • Observe relevant safety regulations. Secure non-reusable hose clips with pliers, BMW No. 13 1 500. • Drain fuel tank. • Remove fuel pump unit (1) and detach hoses (2).

  • Page 127: Removing And Installing Fuel Pump And Fuel Level Sensor

    • [ABS] Bleed the brake system. 16 1 500 C160030 • 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) Note: If fuel pressure is low, check pump, fuel filter, pres- sure regulator and fuel line.
  • Page 128 16.8...

  • Page 129: Exhaust System

    18 Exhaust system Contents Page Removing and installing exhaust system ................3 Removing and installing silencer (muffler) ................3 Removing and installing front exhaust pipes ..............3 18.1...
  • Page 130 18.2...
  • Page 131 11 7 020 C180010 Removing and installing exhaust • Secure the oxygen sensor with special socket wrench insert, BMW No.11 7 020. system Caution: Removing and installing silencer After a trial run, read out Motronic fault memory. (muffler) Tightening torque: •...
  • Page 132 18.4...
  • Page 133 21 Clutch Contents Page 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 21.1...
  • Page 134 21.2...

  • Page 135: Technical Data

    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 Ø mm (in) 13 (0.51) Slave cylinder piston Ø mm (in) 24 (0.94) Clutch fluid DOT 4 brake fluid Clutch plate dia.
  • Page 136 21.4...

  • Page 137: Removing And Installing Clutch

    Removing and installing clutch Secure the clutch with the retaining screws. • Center the clutch plate with centering pin, Removing clutch BMW No. 21 2 673. • Tighten retaining screws alternately in a cross- Preparatory work is as for “Removing wise pattern.

  • Page 138: Removing And Installing Clutch Hydraulic Line

    C210030 Removing and installing clutch Removing and installing clutch hydraulic line slave cylinder • • Remove fuel tank. Remove fuel tank. • Remove the battery. • [ABS] Drain the brake system. Caution: Do not allow brake fluid to come into contact with Caution: painted parts of the motorcycle, because brake fluid Do not allow brake fluid to come into contact with...

  • Page 139: Filling/Bleeding Clutch Line

    • 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.
  • Page 140 21.8...
  • Page 141 23 Gearbox Contents Page 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 ..................8...
  • Page 142 23.2...

  • Page 143: Technical Data

    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...
  • Page 144 23.4...

  • Page 145: Removing And Installing Gear Pedal

    • Pull swinging arm upwards with strap. • • Removing exhaust manifold. Using pull rod, BMW No. 00 8 581, and impact • Remove silencer (muffler). weight, BMW No. 00 8 582, pull out the swinging • Detach plug at oxygen sensor.
  • Page 146 Pull out the thrust rod. • Detaching the gearbox 23 1 820 23 1 820 RS230010 • When removing, pull the gearbox out on guide pins, BMW No. 23 1 820. • Install by following the above work instructions in the reverse order. 23.6...

  • Page 147: Renewing The Shaft Sealing Rings In The Gearbox Housing And Gearbox Cover

    • lips lightly. Install the sealing ring with the sealing lips facing inwards, using slip-over sleeve, BMW No. 23 4 732, and drift, Renew the input shaft sealing ring at the input BMW No. 23 4 731. • Lever the shaft sealing ring out with a screw- driver.

  • Page 148: 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 shaft sealing ring.

  • Page 149: Dismantling Gearbox

    C230012 Dismantling gearbox 80…100 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). •...

  • Page 150: Removing Selector Drum

    C230030 Removing selector drum Dismantling/assembling selector shaft • 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).

  • Page 151: Removing Gearbox Shafts

    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.

  • Page 152: Dismantling/Assembling Input Shaft

    (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 00 7 500 pressure head (arrow) to pull off deep-groove ball bearing (11). KR230090 •...

  • Page 153: Assembling Input Shaft

    KR230080 Assembling input shaft • Oil the bearing surface for constant-speed gear (1) lightly on input shaft (10), and install the constant-speed gear. • Oil the splines in thrust block (2) lightly and install • Place anti-rattle disc (3) on thrust block (2). •...

  • Page 154: Dismantling/Reassembling Output Shaft

    • Turn output shaft (6) and clamp into the vise with soft jaws. • Using universal puller, BMW No. 00 7 500, pull 00 7 500 off deep-groove ball bearing (1) together with shift gearwheel for 2nd gear (4). •...

  • Page 155: Assembling Output Shaft

    1st gear 4th gear 3rd gear 2nd gear 5th gear KR230120 • Assembling output shaft Install needle roller bearing (14). Caution: Note: To avoid damaging the needle roller bearing at the Assembly starts at the shift gearwheel for 4th gear. splines, spread it carefully at the butt joint before in- Before assembly, oil all running surfaces lightly with stalling.

  • Page 156: Checking Endplay

    Transfer output shaft (6) to new position in vise. • Install shift wheel for 5th gear (17) with the recess • for the selector fork facing the 2nd gear shift Attach dial gauge, BMW No. 00 2 510, to dial wheel (3). gauge stand. • •...

  • Page 157: Checking/Adjusting Fully Compressed Length Of Gearbox Shafts, Selector Drum

    Secure dial gauge, BMW No. 23 4 762, in rear mounting hole on measuring stand, Adjusting dimensions for intermediate shaft: BMW No. 23 4 761, and set to 0.2 mm (0.008 in) Maximum deviation preload. from zero ..-0.05 mm (0.002 in) … 0.00 mm/in •...

  • Page 158: Checking/Adjusting Fully-Compressed Length Of Output Shaft

    • Take off the spacing washer. • • Insert zero gauge, BMW No. 23 4 763, in to Remove output shaft from measuring fixture. • measuring stand, BMW No. 23 4 761. Take off spacing washer, deep-groove ball bear- •...

  • Page 159: Checking/Adjusting Fully-Compressed Length Of Input Shaft

    • mounting hole on measuring stand, Place a spacing washer (1) of the determined BMW No. 23 4 761, and set to 0.2 mm (0.008 in) thickness in position and press the deep-groove preload. ball bearing on to the input shaft.

  • Page 160: Checking/Adjusting Fully-Compressed Length Of Selector Drum

    KR230190 Checking/adjusting fully-compressed length of selector drum • Place spacing washer and both thrust washers on the selector drum. • Using depth gauge, determine fully-compressed length “A”. • If necessary, adjust fully-compressed length “A” with a shim washer (arrow). Fully-compressed length: Selector drum ..

  • Page 161: Shimming Selector Shaft

    Shimming selector shaft Caution: If the housing or the complete selector shaft is re- newed, the selector shaft must be measured and shimmed again. KR230220 • Measure dimension “C” from the shoulder on the selector shaft to the back of the sleeve. •...

  • Page 162: Assembling Gearbox

    Installing input, output and • Push slip-over sleeve, BMW No. 23 4 712, on to intermediate shaft the input shaft splines. Note: This is only necessary if the shaft sealing ring is in- stalled.

  • Page 163: Installing Selector Shaft

    C230030 Installing selector shaft Installing selector drum • Place a spacing washer of the determined thick- ness and the input-side thrust washer on selec- tor drum (6) and secure with a small amount of grease. • Swing locking lever (8) out towards the edge of the cover and install the selector drum.

  • Page 164: Assembling Gearbox Housing

    • Using the metering device, apply Loctite 5203 surface sealant to the cover joint face. • Place slip-over sleeve, BMW No. 23 4 732, on C230020 the output shaft. • Place slip-over sleeve, BMW No. 23 4 712, on •...
  • Page 165 C230012 • Insert screws (8) and tighten in a crosswise pat- tern. • Install neutral indicator (4) and clip wire (3) into position. • Install breather (1). Caution: Clean metal particles off the magnet in drain plug (7). • Insert oil drain plug (7). •...
  • Page 166 23.26...
  • Page 167 31 Front fork Contents Page Technical data ..........................3 Removing and installing telescopic fork .................5 Removing and installing telescopic fork ................5 Removing and installing fork bridge .....................5 Removing and installing pot-type joints ....................6 Removing and installing ball thrust bearing ..................7 Removing and installing slider tube bridge .................8 Removing and installing ball joint ......................8 Checking friction at ball joint/ball thrust bearing...
  • Page 168 31.2...

  • Page 169: Technical Data

    Technical data R 850 C R 1200 C Front suspension Type BMW Telelever with external suspension strut Telescopic fork Front wheel caster in normal-load position mm (in) 86 (3.39) Steering lock angle ° 2 x 38 Total suspension travel mm (in) 144 (5.67)
  • Page 170 31.4...

  • Page 171: Removing And Installing Telescopic Fork

    31 5 600 C310020 Removing and installing telescopic • Separate the connecting plug for the ignition/ steering lock in the central electrical equipment fork box. • Detach the instrument holder. Removing and installing telescopic • Detach the headlight holder. fork •...

  • Page 172: Removing And Installing Pot-Type Joints

    Removing and installing pot-type joints the reverse order. • Using a socket wrench insert and internal hexa- gon, BMW No. 31 5 600, tighten the ball joint at the leading link. 31 5 661 Caution: To prevent grease from escaping and the ingress of dirt, ensure that sleeve is correctly located on ball joint.

  • Page 173: Removing And Installing Ball Thrust Bearing

    Press out the threaded journal using a pin, BMW No. 31 5 651, as a support. 31 5 651 GS310120 • Press the threaded journal into the ball thrust bearing using a pin, BMW No. 31 5 651, as a support. 31.7...

  • Page 174: Removing And Installing Slider Tube Bridge

    • • Removing the front mudguard Motorcycle raised on auxiliary stand, BMW No. 00 1 550; front wheel must be clear of ground. • Measure the breakaway moment to left and right from the central position of the handlebar using friction meter, BMW No.

  • Page 175: Assembly Specification For Telescopic Fork

    Assembly specification for telescopic fork: Tightening torque: Caution: Bridge to fork slider To ensure that the fork is installed without trapped (clean thread + Loctite 243)......22 Nm stresses, observe the following instructions and the • specified working sequence precisely. Check that the system moves freely by com- pressing and extending the suspension (but •...

  • Page 176: Dismantling/Reassembling Telescopic Fork

    Remove washer (6). Oil the shaft seal slightly and push it on as far as possible (to stop on slider tube) by striking it lightly with drift, BMW No. 31 5 610, and reduc- ing adapter, BMW No. 31 5 613. •...

  • Page 177: Measuring Telescopic Fork

    Measuring telescopic fork Caution: After an accident, always examine the telescopic fork for cracks and signs of damage. Check slider tube bridge • Check that the slider tube bridge is flat. Caution: Renew slider tube bridge if distorted. Checking runout of fixed tube RS310060 •...

  • Page 178: Removing And Installing Leading Link

    Tighten the ball joint at the leading link with the Spring strut to frame ........40 Nm socket wrench insert and internal hexagon, Spring strut to leading link......40 Nm BMW No. 31 5 600. Tightening torque: Right leading link to engine ......73 Nm Left screw cap (coat thread lightly with Never Seez).....
  • Page 179 32 Steering Contents Page Technical data ..........................3 Removing and installing left handlebar fitting .............5 Removing and installing right handlebar fitting ............6 Removing and installing handlebar ..................7 Removing/installing throttle cable ..................8 32.1...
  • Page 180 32.2...

  • Page 181: Technical Data

    Technical data R 850 C R 1200 C Steering lock angle ° 2 x 38 Steering head tube dia. mm (in) 25 (0.98) Width over mirrors mm (in) 1050 (41.34) 32.3...
  • Page 182 32.4...

  • Page 183: Removing And Installing Left Handlebar Fitting

    C320020 Removing and installing left handlebar fitting • Detach mirror. • Loosen screw (1) for handlebar grip and pull off the grip. • Detach lower section (2) at handlebar fitting. • Pull off clutch switch (3). • Detach combined switch (4). •...

  • Page 184: Removing And Installing Right Handlebar Fitting

    C320030 Removing and installing right handlebar fitting Tightening torque: Brake lever fitting to handlebar....... 8 Nm Brake hose to brake lever fitting ....18 Nm • Detach the mirror. • Remove throttle twistgrip cover (1). • Take out the wire cable adjusting screw (2) and disconnect the wire cable.

  • Page 185: Removing And Installing Handlebar

    Removing and installing handlebar CUB0010 • Remove left/right handlebar fittings. • Remove handlebar. • Install in the reverse order of work. • Install the lower clamp block with the arrow pointing forwards. • Tighten the front clamp block first. Note: The clamp is higher at the front.

  • Page 186: Removing/Installing Throttle Cable

    C320010 Removing/installing throttle cable • Unscrew fuel tank and pull to the rear. • Remove wire cable cover at fitting and discon- nect the wire cable. • Remove cover at air cleaner housing. • Disconnect/remove the wire cable. Note: If necessary, press the nipple out from the rear with a wire hook.
  • Page 187 33 Rear wheel drive Contents Page Technical data ..........................3 Removing, dismantling, reassembling and installing rear wheel drive ..5 Removing rear wheel drive ......................5 Removing input bevel pinion ......................5 Disassembling input bevel pinion ....................7 Removing needle roller bearing for input bevel pinion .................7 Installing needle roller bearing for input bevel pinion ................7 Assembling input bevel pinion ....................8...
  • Page 188 33.2...

  • Page 189: Technical Data

    Technical data R850 C R 1200 C Rear wheel drive Gear tooth pattern Klingelnberg-Palloid spiral bevel Gear ratios 2.75 : 1 2.54 : 1 Number of teeth 33 : 12 33 : 13 Backlash mm (in) 0.07...0.16 (0.0027..0.0063) Taper roller bearing preload mm (in) 0.05...0.1 (0.0020...0.0039) Oil grades Brand-name hypoid gear oil, SAE 90 GL 5...
  • Page 190 33.4...

  • Page 191: Removing, Dismantling, Reassembling And Installing Rear Wheel Drive

    Removing rear wheel drive • Raise the motorcycle with the auxiliary stand, BMW No. 00 1 550. • Drain the oil. • Detach the brake caliper and secure it to the rear frame with a cable strap.
  • Page 192 33 1 700 33 1 516 C330011 • Bolt the rear wheel drive to the retaining fixture, BMW No. 33 1 510/511. • Bolt the locking arm (1) to the retaining fixture. • Screw threaded bushings (2) down on to the rear wheel drive and secure them with the wheel studs.

  • Page 193: Disassembling Input Bevel Pinion

    BMW No. 00 8 573, and threaded spindle extension, BMW No. 00 8 575. • Using puller, BMW No. 00 7 500, pull off both bearings at the same time. Installing needle roller bearing for input bevel •...

  • Page 194: Assembling Input Bevel Pinion

    KR330131 C?????? Assembling input bevel pinion • Heat the inner race (1) to 100 °C (212 °F) and push onto input bevel pinion (2) as far as the stop. • Push the outer race (3) together with the roller cage (4) on to the inner race. •...

  • Page 195: Installing Input Bevel Pinion

    • Press/drive sealing ring (1) with drift, BMW No. 33 1 770, and handle, BMW No. 00 5 550, into threaded ring (2). • Heat the housing to 120 °C (248 °F). • Insert the input bevel pinion (3) complete with spacing washer (4).

  • Page 196: Removing And Dismantling The Crown Wheel

    Force shaft seal (4) out of housing cover with drift. KR33018 • Clamp crown wheel in vice with protective jaws. • Insert thrust block (arrow), BMW No. 33 1 307. • Use puller, BMW No. 33 1 830, to pull off the deep-groove ball bearing. 33.10...

  • Page 197: Assembling/Installing Crown Wheel

    Assembling/installing crown wheel 00 5 500 00 7 500 23 4 670 KR333019 • Using puller, BMW No. 00 7 500, pull taper roller C330230 bearing off crown wheel. • Heat the housing to 80 °C (176 °F). • Insert the outer race in the bearing seat with drift, BMW No.

  • Page 198: Checking/Adjusting Backlash

    Backlash: housing with the knurled screw. (adjust • Attach measuring arm, BMW No. 33 2 604, cen- without oil)..0.07...0.16 mm (0.0027...0.0063 in) trally to crown wheel. C330070 • With the palm of the hand, press the crown wheel into the housing and turn to and fro to check tooth backlash.

  • Page 199: Checking Tooth Contact Pattern

    Checking tooth contact pattern • The tooth contact pattern must be checked if the gear set, housing or input bevel pinion bearing have been renewed. KR330270 • If this contact pattern is obtained, a thinner shim washer must be installed. KR33025 Note: The contact pattern is adjusted at the shim washer (1)

  • Page 200: Shimming Housing Cover

    Using depth gauge, BMW No. 00 2 550, meas- Using drift, BMW No. 33 1 870, and handle, ure distance a. BMW No. 00 5 500, drive in the sealing ring. • Install O-ring and apply a light coat of oil/grease.

  • Page 201: Removing/Installing Rear Swinging Fork

    00 8 581 C330040 • Detach the fixed swinging arm bearing journal. • Using pull rod, BMW No. 00 8 581, and impact weight, BMW No. 00 8 582, pull out the fixed C330030 swinging arm bearing journal. • Remove the swinging arm bearing journal.

  • Page 202: Removing And Installing Taper Roller Bearing

    LT330370 • Press off drive shaft. • Pull the taper roller bearing out with counter-sup- port, BMW No. 00 8 572, and internal puller Caution: 21/2, BMW No. 00 8 571. Avoid scratching painted parts; use an underlay if •...

  • Page 203: Installing Rear Swinging Arm

    C330014 Installing rear swinging arm • Slide swinging arm over drive shaft as far as pos- sible until rubber gaiter connects on housing neck. • Install fixed bearing journal (1). • Screw in free bearing journal (2). • Tighten fixed bearing journal. •...

  • Page 204: Installing Rear Wheel Drive

    C330011 • Installing rear wheel drive [ABS] Check that sensor gap is correct. • Coat splines at sliding element (arrow) with ABS rear Staburags NBU 30 PTM. sensor gap: ..0.50...0.55 mm (0.019...0.021 in) • Offer up the rear wheel drive assembly and guide the sliding element into the drive shaft.

  • Page 205: Removing And Installing Suspension Strut

    Removing and installing suspension strut Note: To remove the suspension strut, support the rear axle. Tightening torque: Suspension strut to swinging arm/rear frame....50 Nm 33.19...
  • Page 206 33.20...
  • Page 207 34 Brakes Contents Page Technical data ..........................3 Removing and installing front brake caliper ..............5 Dismantling and assembling front brake caliper ............6 Dismantling front brake caliper ....................6 Assembling front brake caliper ....................6 Removing and installing rear brake caliper ..............7 Dismantling and assembling rear brake caliper ............8 Dismantling rear brake caliper ....................8...
  • Page 208 Contents Page Removing the ABS unit ......................16 Installing the ABS unit .........................17 Removing and installing ABS relay and relay base ..........18 Removing ABS relay ........................18 Installing the ABS relay .......................18 Removing ABS relay base ......................18 Installing the ABS relay base ....................19 Removing and installing brake lines ................20...

  • Page 209: Technical Data

    Technical data R 850 C R 1200 C Brake fluid DOT 4 Minimum lining thickness mm (in) 1.5 (0.06) Wear indicator: Front brake pads/cutouts in pad material Rear brake pads/hole in wheel-side brake pad backplate enables brake disc to be seen when minimum pad thickness is reached.
  • Page 210 34.4...

  • Page 211: Removing And Installing Front Brake Caliper

    Removing and installing front brake caliper RS340021 • Drain fluid from brake system. • Detach brake line (1). Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint. • Unscrew the brake caliper.

  • Page 212: Dismantling And Assembling Front Brake Caliper

    Do not tilt the brake pistons when installing. Dismantling front brake caliper • Using piston resetting tool (5), • Remove the brake caliper. BMW No. 34 1 500, press the pistons fully back. • • Remove keeper from retaining pin (1). Install the brake pads. •...

  • Page 213: Removing And Installing Rear Brake Caliper

    C330012 Removing and installing rear brake caliper • Drain fluid from brake system. Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint. • Detach the brake line from the brake caliper. •...

  • Page 214: Dismantling And Assembling Rear Brake Caliper

    GS340140 Dismantling and assembling rear Assembling rear brake caliper brake caliper • Coat the new sealing rings with brake fluid and insert them into the left/right brake caliper cylin- Dismantling rear brake caliper ders. • Coat both brake caliper pistons with brake fluid •...

  • Page 215: Removing And Installing Front Brake Disc

    C360020 Removing and installing front brake disc • Degrease brake discs before installing. Note: Installed direction (arrow) of brake discs must be correct. Tightening torque: (clean thread + Loctite 243)......24 Nm Caution: Check/adjust the sensor gap. Sensor gap:.... 0.45...0.55 mm (1.77...2.22 in) 34.9...

  • Page 216: Removing/Installing Rear Brake Disc

    Removing/installing rear brake disc • Remove rear wheel. • Remove the brake caliper. C330013 • Heat the brake disc retaining screws to 120 °C (248 °F) and remove them. Note: Mark the position of the brake disc. The sensor gap setting remains unchanged. •...

  • Page 217: Removing And Installing Front Abs Sensor

    C340050 Removing and installing front ABS sensor • Remove fuel tank. • Separate plug connector (1) in sensor line. • Remove sensor (2) with Torx T 25. • Install by following the above work instructions in the reverse order. Caution: Run the sensor line correctly.

  • Page 218: Adjusting Front Abs Sensor Gap

    Attach dial gauge holder (1), BMW No. 00 2 500, plates. with dial gauge, BMW No. 00 2 510, and meas- uring shoe (2), BMW No. 34 2 510, to the fork Sensor gap:.... 0.45...0.55 mm (1.77...2.22 in) slider tube.

  • Page 219: Removing And Installing Rear Abs Sensor

    C340070 Removing and installing rear ABS sensor Note: To install spacing shims, pull the sensor out by a small amount only and pull the spacing shims out upwards. • Before removing/installing, clean the sensor bore. • Using Torx T 25, detach sensor (1). •...

  • Page 220: Adjusting Rear Abs Sensor Gap

    Screw dial gauge holder with measuring shoe Caution: and extension, BMW No. 34 2 520, with dial After adjusting, check that the sensor wheel is free gauge, BMW No. 00 2 510, firmly to the sensor to turn at all points on its circumference. mount. •...

  • Page 221: Removing And Installing Rear Brake Master Cylinder

    Brake pedal to footrest plate the reverse order. (thread free from grease) ......37 Nm • Attach non-reusable hose clip with pliers, BMW No. 13 1 500. Caution: Bleed the brake system carefully. Check/adjust piston rod snifting-action play. Tightening torque: Master cylinder to footrest plate .....

  • Page 222: Removing And Installing Abs Unit

    Caution: Caution: Work on the ABS unit is only to be performed by an Switch off ignition, disconnect and insulate the authorized BMW workshop. ground (earth) strap. • Remove cover (2) from ABS control unit, press Removing the ABS unit the lock in with a screwdriver and pull the cover •...

  • Page 223: Installing The Abs Unit

    Installing the ABS unit • Install the ABS unit (6). • Connect the central plug (5). Caution: Make sure the cable is not at an angle, or its insula- tion may be damaged. • Reconnect the 2-pin plug in the correct position, pushing the two halves fully together, and press the two wires into the center (smaller) cable en- tries.

  • Page 224: Removing And Installing Abs Relay And Relay Base

    Removing and installing ABS relay • Tighten the nuts. and relay base Caution: Always use new self-locking nuts. Removing ABS relay • Install a new cover (1). Caution: When sliding the cover on, make sure that all cables are correctly located in their cable entries. Scrap the old cover.

  • Page 225: Installing The Abs Relay Base

    Installing the ABS relay base • Bend up the contact interlock on the plug. • Insert the contact into the relay base. Caution: The contact must be heard to engage and must be firmly located. • Insert the ABS relay with the FAG inscription fac- ing the detent hook.

  • Page 226: Removing And Installing Brake Lines

    Removing and installing brake lines Removing and installing front brake line C340020 34.20...

  • Page 227: Removing And Installing Rear Brake Line

    Removing and installing rear brake line C340030 34.21...
  • Page 228 • Drain fluid from brake system. Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint. • Remove fuel tank. • Remove brake lines. • Install by following the above work instructions in the reverse order.
  • Page 229 36 Wheels and tyres Contents Page Technical data ..........................3 Removing and installing front wheel .................5 Removing front wheel ........................5 Installing front wheel ........................5 Removing and installing wheel bearings ................6 Removing/installing rear wheel ....................8 Static balancing of front wheel/rear wheel ..............9 Checking front/rear wheel rim for runout ..............10 Removing/installing spokes...
  • Page 230 36.2...

  • Page 231: Technical Data

    Technical data R 850 C R 1200 C Rim size Front 2.50 x 18 MT H 2 Rear 4.00 x 15 MT H 2 Max. vertical/lateral runout mm (in) 1.3 (0.05) Tyre size Front 100/90 x 18 56H Tubeless Rear 170/80 x 15 83H Tubeless Tyre pressures (cold) Solo...
  • Page 232 36.4...

  • Page 233: Removing And Installing Front Wheel

    Apply a light coating of Molykote paste to the • Place the motorcycle on the auxiliary stand, quick-release axle/install it. • BMW No. 00 1 550. Tighten the retaining screw (1). • • Remove brake calipers. Install the brake calipers.

  • Page 234: Removing And Installing Wheel Bearings

    31 4 800 36 5 512 RS360022 • Clamp a drift, BMW No. 36 5 513, into the vice and place the wheel on it with the wide bearing in contact. • Place a spacing ring, BMW No. 31 4 800, be- tween the wheel hub at the right and the claws of the internal puller.
  • Page 235 00 5 500 36 5 512 36 5 513 C360040 • Clamp a drift, BMW No. 36 5 513, into the vice and place the wheel on it with the wide bearing (1) in contact. • Install spacer tube (2).

  • Page 236: Removing/Installing Rear Wheel

    C360010 Removing/installing rear wheel • Place the motorcycle on the auxiliary stand, BMW No. 00 1 550. Caution: Only use wheel studs with length code 60. Do not oil or grease wheel studs! Contact faces on rear wheel drive and hub must be clean and free of grease.

  • Page 237: Static Balancing Of Front Wheel/Rear Wheel

    Lightly preload bearing with knurled nut (3). • At the rear wheel, bolt the mounting fixture (4), BMW No. 36 3 613, to the centering collar side with the balancing shaft. • Align the balancing fixture, BMW No. 36 3 600, with knurled screws and bubble gauge (5/6).

  • Page 238: Checking Front/Rear Wheel Rim For Runout

    • Remove tyre. • Install the balancing shaft (1), BMW No. 36 3 606, with measuring bushing (2) and nut (3), BMW No. 36 3 616, in the front wheel bearings. • Lightly preload bearing with knurled nut (3). •...

  • Page 239: Removing/Installing Spokes

    Removing/installing spokes Centering lateral runout GS360090 C360050 • Determine maximum deviation (plus (+) and mi- nus (-)). • Caution: To center the wheel, the spoke nipples must be It is not permitted to replace more than one spoke. tightened on the side directly opposite the larg- est deviation.
  • Page 240 36.12...
  • Page 241 46 Frame Contents Page Technical data ..........................3 Removing and installing rear mudguard .................5 Removing/installing front mudguard .................5 Removing and installing front frame .................6 Removing and installing rear frame ...................8 Removing/installing footrest supports ................10 Removing and installing side (prop) stand ..............10 Checking running gear ......................11 Measuring wheel track offset...
  • Page 242 46.2...

  • Page 243: Technical Data

    Technical data R 850 C R 1200 C Location of manufacturer’s type plate / frame number On frame, at right Length, overall mm (in) 2340 (92.1) Max. height excl. mirrors mm (in) 1130 (44.5) Width over mirrors mm (in) 1050 (41.3) Width over rider’s footrests mm (in) 665 (26.2) Width over pillion footrests...
  • Page 244 46.4...

  • Page 245: Removing And Installing Rear Mudguard

    C460020 Removing and installing rear Removing/installing front mudguard mudguard • Take out the front retaining screws (1) • Remove the nuts at the rubber cover (2) Caution: The locking lug (3) of the retaining elements must engage in the hole. If necessary, bend the retaining element.

  • Page 246: Removing And Installing Front Frame

    C460060 • Removing and installing front frame Heat the ball joint mount at the leading link to max. 120 °C (248 °F) and detach it. • Remove seat. • Remove side trim. Caution: • Remove fuel tank. Avoid scratching the leading link. •...
  • Page 247 • Remove the horn. • Remove the air guides to the oil cooler. • Remove the oil cooler. • Remove frame. Note: Only loosen the threaded connections at the lower rear frame. • Install by following the above work instructions in the reverse order.

  • Page 248: Removing And Installing Rear Frame

    C460030 • Removing and installing rear frame Remove suspension strut. • Attach stand to motorcycle with extension bush- Note: ings, BMW No. 00 1 520/529. Press to the rear at the top. • Remove seat. • • Remove side trim.
  • Page 249 Loosen screws for right swinging arm bearing. 00 8 582 00 8 581 C330040 • Using pull rod, BMW No. 00 8 581, and impact weight, BMW No. 00 8 582, pull out the swinging arm bearing. • Remove the left swinging arm bearing.

  • Page 250: Removing/Installing Footrest Supports

    C460040 Removing/installing footrest Removing and installing side (prop) supports stand Tightening torque: Footrest support to engine M12 bolt............71 Nm M8 bolt............21 Nm Brake master cylinder to footrest assembly ..8 Nm Brake pedal to footrest assembly ....37 Nm C460050 •...

  • Page 251: Checking Running Gear

    Permissible • Place track alignment gauge, wheel track offset (S): ....9 mm (0.35 in) BMW No. 36 3 920, against the left or right side of the motorcycle. Key to measurement result: Minus sign = track offset to left...
  • Page 252 EXAMPLE: Formula: – ----- - ----- - Fixed value A (length of measuring stops) A = 50.0 mm (1.97 in) Half of rear wheel rim width ----- - = 72.5 mm (2.85 in) Measured value B (mean value) B = 70.0 mm (2.76 in) Half of front wheel rim width = 54.5 mm (2.16 in) ----- -...
  • Page 253 51 Equipment Contents Page Removing and installing ignition switch/steering lock ...........3 Removing and installing ignition/light switch ..............3 Removing and installing lock barrel ..................3 Drilling out lock barrel ..........................3 Removing and installing lock barrel for fuel tank filler cap ........4 Drilling out lock barrel ..........................4 51.1...
  • Page 254 51.2...
  • Page 255 Press lock barrel down until keeper engages. • Install steering lock with serrated-screw socket wrench insert, BMW No. 51 0 510. Drilling out lock barrel • Use a 4-5 mm (0.16-0.20 in) dia. drill bit to drill Tightening torque: the full length of the lock barrel.
  • Page 256 GS510040 Removing and installing lock barrel for fuel tank filler cap Note: Prevent screws from falling into fuel tank: cover fuel tank filler neck with cloth. • Open cap/remove lower part of cap (1). • Insert key in lock barrel and press down on re- tainer (2).
  • Page 257 52 Seat Contents Page Removing and installing seat ....................3 52.1...
  • Page 258 52.2...
  • Page 259 C520020 Removing and installing seat • Take out screw (1) for seat back. • Pull out the locking pin and take off the seat back. C520010 52.3...
  • Page 260 52.4...
  • Page 261 61 General electrical equipment Contents Page Technical data ..........................3 Removing and installing central electrical equipment box ........5 Relay positions (central electrical equipment box) ...........6 Connections to fuses: .........................6 Frame wiring harness ........................7 Wiring harness View from left ............................8 Wiring harness View from right ..........................12 61.1...
  • Page 262 61.2...

  • Page 263: Technical Data

    Technical data R 850 C R 1200 C Battery Amp/h 19 61.3...
  • Page 264 61.4...

  • Page 265: Removing And Installing Central Electrical Equipment Box

    Removing and installing central electrical equipment box Caution: Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. C610020 • Detach the central electrical equipment box. • If necessary, detach the complete wiring harness and remove it with the central electrical equip- ment box.
  • Page 266 9 10 C610010 Relay positions (central electrical equipment box) 1. Flasher unit 2. Fuel gauge/display damping 3. Encoding plug for Motronic 4. Starter motor relay 5. Lighting relay 6. ABS warning relay 7. Motronic relay 8. Fuel pump relay 9. Horn relay 10.Load-relief relay 11.Fuse Connections to fuses:...

  • Page 267: Frame Wiring Harness

    Frame wiring harness Caution: Use (yellow) galvanized bolts for the ground (earth) connection to the engine. Screws with unsuitable corrosion proofing can cause the electrical resistance to rise as high as Run wiring without kinking and avoid risk of abra- sion.

  • Page 268: Wiring Harness

    Wiring harness View from left C619020 61.8...
  • Page 269 C619021 61.9...
  • Page 270 C619022 61.10...
  • Page 271 C619023 61.11...

  • Page 272: Wiring Harness

    Wiring harness View from right C619030 61.12...
  • Page 273 C619011 61.13...
  • Page 274 C619012 61.14...
  • Page 275 C619013 61.15...
  • Page 276 61.16...
  • Page 277 62 Instruments Contents Page Technical data ..........................3 Removing and installing instrument cluster ..............5 Dismantling and assembling instrument cluster ............5 62.1...
  • Page 278 62.2...
  • Page 279 Technical data R 850 C R 1200 C Instrument cluster Instrument lighting T6.5 12 V 3 W Telltale and warning lights turn indicators/others T6.5 12 V 3 W/1.7 W 62.3...
  • Page 280 62.4...
  • Page 281 C620010 Removing and installing instrument cluster • Separate the combined instrument plug in the electrical equipment box. Dismantling and assembling instrument cluster • To remove the speedometer, take out the screw (arrow) located inside for the trip distance re- corder reset knob, and pull off the knob. 62.5...
  • Page 282 62.6...
  • Page 283 63 Lights Contents Page Technical data ..........................3 Removing and installing headlight ..................5 Adjusting headlight .........................5 63.1...
  • Page 284 63.2...
  • Page 285 Technical data R 850 C R 1200 C Headlight circular, with halogen bulb Bulbs High beam/low beam H 4 60/55 W halogen, asymmetric Parking light 12 V/4 W Rear light/brake light 12 V / 5/21 W Flashing turn indicator 12 V/21 W 63.3...
  • Page 286 63.4...
  • Page 287 Removing and installing headlight Caution: Switch off ignition. Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. Do not touch inner surface of reflector or bulbs with bare hands. Adjusting headlight • Correct the beam angle after slightly loosening the headlight mountings.
  • Page 288 63.6...

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