BMW R 1200 C, Repair Manual

Page 1: ...BMW AG Motorcycle Division After Sales R 850 C R 1200 C Repair Manual ...

Page 2: ...ales 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 Order number 01 50 7 654 051 ...

Page 3: ...l 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...

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Page 5: ... 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 f...

Page 6: ... 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...

Page 7: ...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 Contents Group Chapter ...

Page 8: ...34 Brakes 36 Wheels and tyres 46 Frame 51 Equipment 52 Seat 61 General electrical equipment 62 Instruments 63 Lights Group Chapter ...

Page 9: ...ections 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 ...

Page 10: ...erating fluid level 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 Tigh...

Page 11: ...itial 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 alter...

Page 12: ...er 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 Tightenin...

Page 13: ...o 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...

Page 14: ...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 Loctit...

Page 15: ...l 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 ti...

Page 16: ...ite 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 General 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 ...

Page 17: ... 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 bottl...

Page 18: ...00 10 ...

Page 19: ...k 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 ...

Page 20: ...lter 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 eCaution 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 9...

Page 21: ... 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 while at regular operating temperature eCaution Note that the interior of the gearbox is slightly pres surised Slacken off oil drain plug 4 so that the pressure d...

Page 22: ...e seat Remove right air cleaner trim panel Remove left and right trim panels eCaution 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 Pull the plug connector off the fuel pump assem bly Lift off fuel tank C160010 13 3 010 ...

Page 23: ...tion 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 ...

Page 24: ...he 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 pane...

Page 25: ...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 nut...

Page 26: ...rops 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 gr...

Page 27: ...m lining thickness 1 5 mm 0 06 in 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 ...

Page 28: ...ning 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 c...

Page 29: ...ubber 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 eCaution 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 Connect the brake bleeding device to the bleed screw on the right brake caliper Open the bleed ...

Page 30: ...ight 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 the reverse order of re moval Brake f...

Page 31: ...ntil 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 eCaution 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...

Page 32: ... screw at pressure modulator 9 Nm Checking clutch operating fluid level Inspections I II and III eCaution 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 eCaution With the clutch lining in new condition the surface of the fluid arrow must ...

Page 33: ...rip 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 EP2 Checking function of side prop stand contact switch Inspections I II III and IV Place the motorcycle on the auxiliary stand BMW N...

Page 34: ...en 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 0 30 mm 0 012 in X Tightening torque Locknut 8 Nm After adjusting check valv...

Page 35: ... 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...

Page 36: ... 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 r...

Page 37: ...ing reassembling valve gear holder 23 Removing cylinder head 25 Dismantling checking repairing and re assembling cylinder head 26 Removing and installing valves 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 cylin...

Page 38: ...evel 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 46 Installing timing chain tensioning and slide rails 46 Installing auxiliary shaft timing chains 46 Assemb...

Page 39: ...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 ...

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Page 41: ...ort 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 Op...

Page 42: ...mit 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 Exhaust 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 i...

Page 43: ...t 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 clear...

Page 44: ...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 M...

Page 45: ...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 100 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 3...

Page 46: ...16 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 T...

Page 47: ...11 11 Sectioned drawing of engine ...

Page 48: ...11 12 Lubricating oil circuit ...

Page 49: ...11 13 Coolant circuit ...

Page 50: ...11 14 ...

Page 51: ...etach 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 b...

Page 52: ...or 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 ...

Page 53: ... 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 the right and pull the shaft out to the l...

Page 54: ...ing 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 ...

Page 55: ...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 eCaution Trap escaping oil 12 3 510 RS110020 ...

Page 56: ...roke 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 ...

Page 57: ...on 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 eCaution 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 ...

Page 58: ...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 ...

Page 59: ...earing 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 eCaution Do not accidentally confuse rocker shafts and push rods RS110080 M8 x 40 M8 x 40 M8 x 30 ...

Page 60: ...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 ...

Page 61: ...11 25 Removing cylinder head RS110110 M6 x 30 M6 x 30 M6 x 30 M10 x 70 ...

Page 62: ...ioner 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 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...

Page 63: ... 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 ...

Page 64: ...aged or not to correct dimensions Determine actual diameter of valve guide using micrometer Open out bore with Ø12 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...

Page 65: ... 5 mm 0 20 in dia drift BMW No 11 5 602 eCaution 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 eCaution Ensure that valve collets are correctly seated in the valve stem grooves Relieve tension on valve springs Check v...

Page 66: ...nder 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 eCaution Do not accidentally confuse pistons piston pins or piston rings RS110170 1 ...

Page 67: ...echnical 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 3rd groove equal chamfer ring 2nd groove micro chamfer ring 1st groove asymmetric convex oval section a See Technical data eCaution The tubular spring ring gap must be at 180...

Page 68: ...ed eCaution Do not accidentally interchange conrods or bearing shells Install conrods Installed direction of conrods lettering facing up eCaution Oil the bearings Screw the big end bolts in by hand then tighten them with a tightening angle indicator BMW No 11 2 500 eCaution 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 ...

Page 69: ...effect signal transmitter plug 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 RS1102...

Page 70: ...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 6...

Page 71: ...he 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 5 640 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 ...

Page 72: ...ve oil pump cover 1 Remove complete oil pump 2 together with cooling oil pipe 3 and dismantle eCaution 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 ...

Page 73: ...with special tool BMW No 11 5 640 Remove the clutch Carefully lever radial shaft seal out using a screwdriver eCaution 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 ...

Page 74: ...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 ...

Page 75: ...ove 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 35 M6 x 35 M6 x 35 M6 x 35 M6 x 35 M6 x 50 M6 x 25 M6 x 50 ...

Page 76: ...11 40 Removing crankshaft auxiliary shaft and timing chain tensioning and slide rails RS110290 ...

Page 77: ...er 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 eCaution Do not accidentally confuse the conrods Checking conrods Check conrod dimensions a See Technical data eCaution Sintered metal conrods must never ...

Page 78: ...Enter measured values on record sheet a See Technical data eCaution The crankshaft can only be reground in grinding stage 0 after this it must be rehardened and fin ished Grinding stages are identified 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 ...

Page 79: ...red 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...

Page 80: ...semble conrods Using tightening angle gauge 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 ...

Page 81: ...s screw them in by hand and tighten with angle gauge BMW No 11 2 210 eCaution 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 ...

Page 82: ...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 auxiliary shaft timing chains eCaution Timing chains 2 must mesh fully with auxiliary shaft sprockets RS110291 u 2 1 ...

Page 83: ...ond 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 ...

Page 84: ... 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 ...

Page 85: ...t 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 ...

Page 86: ...stall 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 ...

Page 87: ... pipe 2 eCaution 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 eCaution 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 ...

Page 88: ...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 eCaution Use a new sealing ring X Tightening torque M 6 screw 10 Nm Banjo sc...

Page 89: ...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 eCaution Always install pistons and cylinders in pairs Do not accidentally confuse pistons or piston pins Piston size identification On piston crown A B AB for either A or B cylinder and on cylinder A B RS110430 X...

Page 90: ...g 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 ...

Page 91: ...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 si...

Page 92: ...arance with adjusting screw and lock into position Valve clearances with engine 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 ...

Page 93: ...h 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 ca...

Page 94: ...h 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 ...

Page 95: ...ositioning the bearings Rocker end float min 0 05 mm 0 002 in max 0 40 mm 0 016 in Install cylinder head cover eCaution 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 ...

Page 96: ...r 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 eCaution 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 Tight...

Page 97: ...ition 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 ...

Page 98: ...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 ...

Page 99: ...h 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 ...

Page 100: ...11 64 ...

Page 101: ...t 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 10 Timing the ignition 11 12 Engine electrics ...

Page 102: ...12 2 ...

Page 103: ...e 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...

Page 104: ...12 4 ...

Page 105: ...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 Check ignition coil resistance Test with BMW MoDiTeC 12 3 520 C120030 ...

Page 106: ... 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 connecting leads at the alternator Remove the alternator Install by following the above work instructions in the reverse order Poly V belt adjusting procedure ...

Page 107: ...e 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 MoDiTeC 1 2 3 RS120050 ...

Page 108: ...se 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 ...

Page 109: ...rk 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 threaded pin Install cover 11 Attach ...

Page 110: ...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 Adhesi...

Page 111: ...g 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 ...

Page 112: ...12 12 ...

Page 113: ...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 Removing and installing Motronic control unit 7 13 Fuel preparation and control ...

Page 114: ...13 2 ...

Page 115: ...200 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 ...

Page 116: ...13 4 ...

Page 117: ...ng 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 ...

Page 118: ...alled 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 eCaution The keeper 2 must be ins...

Page 119: ...ntrol unit Remove fuel tank eCaution 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 ...

Page 120: ...13 8 ...

Page 121: ...ving 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 7 16 Fuel tank and lines ...

Page 122: ...16 2 ...

Page 123: ...ank 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 ...

Page 124: ...16 4 ...

Page 125: ...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 ...

Page 126: ...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 eCaution 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 ...

Page 127: ...p 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 AB...

Page 128: ...16 8 ...

Page 129: ...18 1 Contents Page 18 Removing and installing exhaust system 3 Removing and installing silencer muffler 3 Removing and installing front exhaust pipes 3 18 Exhaust system ...

Page 130: ...18 2 ...

Page 131: ...eCaution 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 eCaution After a trial run read out Motronic fault memory X Tightening torque Oxygen sensor coat thread with Never Seez 45 Nm Removing and install...

Page 132: ...18 4 ...

Page 133: ...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 ...

Page 134: ...21 2 ...

Page 135: ...g 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 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 ...

Page 136: ...21 4 ...

Page 137: ...Clutch housing to crankshaft oil screw threads lightly Initial tightening 40 Nm Wrench angle 32 Install clutch eCaution 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 poi...

Page 138: ...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 eCaution Do not allow brake fluid to come into contact with painted parts of the motorcycle because brake fluid destroys paint Detach cl...

Page 139: ...ndlebar fully to right eCaution 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 eCaution During the bleeding operation the brake fluid must not drop below the MIN...

Page 140: ...21 8 ...

Page 141: ... bearing on intermediate shaft 11 Dismantling assembling input shaft 12 Dismantling input shaft 12 Assembling input shaft 13 Dismantling reassembling output shaft 14 Stripping down output shaft 14 Assembling output shaft 15 Checking endplay 16 Checking adjusting fully compressed length of gearbox shafts selector drum 1 7 Checking adjusting fully compressed length of intermediate shaft 17 Checking ...

Page 142: ...23 2 ...

Page 143: ... 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 ...

Page 144: ...23 4 ...

Page 145: ...wheel drive unit Detach brake hose holder Press off left swinging arm bearing cap eCaution 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 and impact weight BMW No 00 8 582 pull out the swinging arm bearing Rem...

Page 146: ... 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 ...

Page 147: ...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 eCaution 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 shaf...

Page 148: ...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...

Page 149: ...nd 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 eCaution 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 Strike lightly with a plastic faced hammer to re ...

Page 150: ...or 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 ...

Page 151: ... intermediate shaft eCaution 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...

Page 152: ...g 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...

Page 153: ...ckness as the one previously removed Compress spring cluster 4 and insert the split segment washer 6 in the ring groove Install guide ring 7 with shoulder facing over segment disc 6 Check fuly compressed length and adjust if nec essary a 23 19 Install spacing washer 8 of the determined thickness and press on deep groove ball bear ing 9 Check endplay of spring cluster 4 L Note If endplay is greater...

Page 154: ... gearwheel 7 Remove circlip 8 support washer 9 shift gearwheel for 3rd gear 10 and needle roller bearing 11 Remove support washer 12 4th gear shift wheel 13 needle roller bearing 14 and support washer 15 Remove circlip 16 and sliding gearwheel for 5th gear 17 Turn output shaft 6 and clamp into the vise with soft jaws Using universal puller BMW No 00 7 500 pull off deep groove ball bearing 1 togeth...

Page 155: ...her 12 and needle roller 11 Install shift wheel for 3rd gear 10 with pockets facing away from the 4th gear shift wheel 13 Install support washer 9 and circlip 8 After installing the 3rd and 4th shift gearwheels measure endplay a 23 16 Install sliding gear 7 with the recess for the se lector fork facing the shift gearwheel for 3rd gear 10 Install support washer 18 and needle roller bearing 19 Insta...

Page 156: ...all bear ing 1 Check endplay at 2nd a 23 16 Checking endplay Attach dial gauge BMW No 00 2 510 to dial gauge stand Apply the dial gauge to the edge of the gear wheel and check endplay eCaution If endplay is beyond the permitted tolerances this indicates either an assembly error or wear in the needle roller bearings the support or spacing wash ers or the shift gear Check for wear and renew the affe...

Page 157: ...o 23 4 765 on the intermediate shaft Place deep groove ball bearing on measuring disc Insert intermediate shaft in measuring stand Using dial gauge measure deviation from zero of dimension B at inner bearing race The deviation from zero is equivalent to the thick ness C of spacing washer 1 Place a spacing washer 1 of the thickness just determined on the inner bearing race and check deviation from ...

Page 158: ...e output shaft Place the deep groove ball bearing on the meas uring disc Insert the output shaft into the measuring stand Using the dial gauge measure the deviation from zero of dimension B at the inner bearing race The deviation from zero represents thickness C of spacing washer 1 Place spacing washer 1 of the thickness just determined on the inner bearing race and check deviation from zero A B C...

Page 159: ...roove ball bearing on the meas uring disc Insert input shaft with adapter disc BMW No 23 4 767 in measuring stand Using the dial gauge measure deviation from zero to dimension B at the inner bearing race The deviation from zero represents the thickness C of spacing washer 1 Place a spacing washer 1 of the determined thickness on the inner bearing race and check the deviation from zero A B C eCauti...

Page 160: ...ace 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 111 80 111 90 mm 4 402 4 406 in KR230190 A ...

Page 161: ...ldered bush ing to cover joint face Measure dimension B from shouldered bush ing to housing joint face Measure dimension C from the shoulder on the selector shaft to the back of the sleeve Determine endplay as follows Dimensions A B D Dimensions D C E Dimensions E thickness of spacing washer endplay Endplay Selector shaft 0 1 0 3 mm 0 004 0 012 in KR230200 A KR230210 B KR230220 C ...

Page 162: ...osition illustrated Push slip over sleeve BMW No 23 4 712 on to the input shaft splines L Note This is only necessary if the shaft sealing ring is in stalled Heat the bearing points on the cover to 80 100 C 176 212 F Insert the input output and intermediate shafts together eCaution Check that the gearbox shafts are correctly seated Install the 1st 3rd gear and 2nd 4th gear selector forks C230100 h...

Page 163: ... 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 Swing locking lever 8 towards selector drum 6 and engage it in position together with guide plate 7 Place shift forks 5 10 in the guide tracks Install selector shafts 3 Install locking pin 11 Place thrust washer 4 on the select...

Page 164: ...ng in position and screw it down Using the metering device apply Loctite 5203 surface sealant to the cover joint face Place slip over sleeve BMW No 23 4 732 on the output shaft Place slip over sleeve BMW No 23 4 712 on the input shaft Place slip over sleeve BMW No 23 4 612 on the selector shaft Heat the bearing seats in the housing to 80 100 C 176 212 F and place the hous ing on the cover C230090 ...

Page 165: ... the magnet in drain plug 7 Insert oil drain plug 7 Insert oil filler and level check plug 2 with a new sealing ring Install shift lever 6 in the correct position L Note In the correct position the mark on the selector lever dot is aligned with the mark on the selector shaft line After assembling the gearbox perform a functional check C230012 1 4 7 6 5 3 8 2 C230130 6 ...

Page 166: ...23 26 ...

Page 167: ... bridge 8 Removing and installing ball joint 8 Checking friction at ball joint ball thrust bearing 8 Assembly specification for telescopic fork 9 Dismantling reassembling telescopic fork 10 Dismantling telescopic fork 10 Assembling telescopic fork 10 Measuring telescopic fork 11 Check slider tube bridge 11 Checking runout of fixed tube 11 Removing and installing leading link 12 Dismantling reassem...

Page 168: ...31 2 ...

Page 169: ...otal suspension travel mm in 144 5 67 Fixed tube surface Hard chrome plated Extl dia of fixed fork tubes mm in 35 0 1 38 Maximum permissible runout of fixed fork tube mm in 0 4 0 016 Telescopic fork oil approved grades BMW telescopic fork oil Fill quantity in each fork leg l Imp pint US quart 0 470 0 8275 0 4966 Suspension strut Type Suspension strut with coil spring and twin tube gas filled shock...

Page 170: ...31 4 ...

Page 171: ...hexa gon on fixed tube Removing and installing fork bridge Unscrew fuel tank and pull to the rear Separate the connecting plug for the ignition steering lock in the central electrical equipment box Detach the instrument holder Detach the headlight holder Detach handlebar from fork bridge Force off cap from fork bridge mount on frame with an M6 screw thread length at least 25 mm 0 98 in Unfasten sc...

Page 172: ...bridge and frame clean thread Loctite 243 130 Nm Threaded connection between fork bridge and fixed tube free from oil and grease 35 Nm Handlebar at fork bridge install the lower clamping block facing forwards direction of arrow and tighten the front clamp first 21 Nm Instrument holder at fork bridge 9 Nm Headlight holder at fork bridge 15 Nm Removing and installing pot type joints Remove dust cove...

Page 173: ... Press out the threaded journal using a pin BMW No 31 5 651 as a support Press the threaded journal into the ball thrust bearing using a pin BMW No 31 5 651 as a support Heat the fork bridge to 100 C 212 F and press in the ball thrust bearing with pin BMW No 31 5 651 and bushing BMW No 31 5 653 Install retaining ring C310050 1 GS310110 31 5 651 GS310120 31 5 651 31 5 651 C310060 31 5 653 ...

Page 174: ...2701 130 Nm Removing and installing ball joint Mount the slider tube bridge in retaining fixture BMW No 31 5 620 Unscrew tighten ball joint with 46 mm 1 81 in socket wrench insert BMW No 31 5 630 in conjunction with protective ring BMW No 31 5 632 X Tightening torque Ball joint to slider tube bridge apply Never Seez to thread 230 Nm Checking friction at ball joint ball thrust bearing Motorcycle ra...

Page 175: ...orque at this point Screw slider tube bridge to leading link X Tightening torque Leading link at ball joint clean thread Loctite 2701 130 Nm Using a strap or similar pull fork towards frame until the fully retracted fixed tubes only need to be pulled out slightly to secure them to the fork bridge Secure fixed tubes to the fork bridge X Tightening torque Screw connection between fixed tube and fork...

Page 176: ...82 Imp pint 0 49 US quart Oil grade in telescopic fork BMW telescopic fork oil L Note No oil changes required during services unit is maintenance free Install fixed tube Install 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 Install retaining ring and dust cover At...

Page 177: ...bridge Check that the slider tube bridge is flat eCaution Renew slider tube bridge if distorted Checking runout of fixed tube Place both ends of fixed tube in V blocks Rotate fixed tube slowly and check with dial gauge while doing so eCaution Do not straighten distorted fixed tubes always re new them Permissible runout 0 4 mm 0 016 in RS310060 ...

Page 178: ...se to the axle before installing Tighten the ball joint at the leading link with the socket wrench insert and internal hexagon BMW No 31 5 600 X Tightening torque Right leading link to engine 73 Nm Left screw cap coat thread lightly with Never Seez 42 Nm Leading link to ball joint use a new nut or clean thread Loctite 2701 130 Nm Spring strut to leading link 40 Nm Dismantling reassembling leading ...

Page 179: ...nts Page 32 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 Steering ...

Page 180: ...32 2 ...

Page 181: ...32 3 32 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 ...

Page 182: ...32 4 ...

Page 183: ...destroys paint Detach the clutch line Loosen the retaining screw 5 for the clutch fit ting and pull the fitting off Unscrew fuel tank and pull to the rear Take off the central electrical equipment box cover Pull off the combined switch plug Pull off the clutch switch plug Install by following the above work instructions in the reverse order Align the clamp joint line with the punch mark on the han...

Page 184: ...h painted parts of the motorcycle because brake fluid destroys paint Detach the brake line Loosen the retaining screw for the brake lever fit ting 6 and pull the fitting off Unscrew fuel tank and pull to the rear Take off the central electrical equipment box cover Pull off the combined switch plug Pull off the brake light switch plug Install by following the above work instructions in the reverse ...

Page 185: ...e clamp is higher at the front eCaution Ensure that brake hoses are correctly located X Tightening torque Clamp to fork bridge 21 Nm Handlebar adjusting dimension Standard Police Distance from turn indicator switch to fuel tank with handlebar at full left or right lock variable 30 50 mm 1 18 1 97 in Optional extra Easy Rider Distance from turn indicator switch to fuel tank with handlebar at full l...

Page 186: ...n nect the wire cable Remove cover at air cleaner housing Disconnect remove the wire cable L Note If necessary press the nipple out from the rear with a wire hook Install by following the above work instructions in the reverse order eCaution Install wire cable without kinking Adjust wire cable a See Group 00 A A B B C320010 ...

Page 187: ...dismantling the crown wheel 10 Assembling installing crown wheel 11 Checking adjusting backlash 12 Checking tooth contact pattern 13 Shimming housing cover 14 Installing housing cover 14 Installing splined element 14 Removing installing rear swinging fork 15 Removing rear swinging arm 15 Removing and installing taper roller bearing 16 Removing and installing flexible gaiter 16 Removing drive shaft...

Page 188: ...33 2 ...

Page 189: ... lower edge of thread in oil filler hole app 0 20 0 35 0 21 During oil changes l Imp pint US quart up to lower edge of thread in oil filler hole app 0 18 0 32 0 19 Drive shaft Layout Two piece shaft with universal joints at each end central sliding joint and integral torsonal vibration damper enclosed in swinging arm Swinging arm Swinging arm length mm in 611 75 24 09 from arm pivot point to centr...

Page 190: ...33 4 ...

Page 191: ...frame with a cable strap Remove sensor 1 for the speedometer signal Remove ABS sensor 2 Remove rear wheel Heat the brake disc retaining screws to 120 C 248 F L Note Mark the position of the brake disc The sensor gap setting remains unchanged Detach the rear wheel drive and pull it off the drive shaft Removing input bevel pinion Press out splined section of shaft If necessary remove install circlip...

Page 192: ...nch insert and reducing ring BMW No 33 1 720 L Note If necessary use cross handle with two tubular ex tensions Pull off thrust ring 4 Heat the housing to max 120 C 248 F and un screw threaded ring 5 with pin wrench BMW No 33 1 700 To remove the input bevel pinion 6 remove the crown wheel a See Removing crown wheel Heat the bearing seat to max 120 C 248 F Using an aluminium drift carefully force th...

Page 193: ...roll er bearing cage 6 and outer race 7 Removing needle roller bearing for input bevel pinion Heat the housing to 130 C 266 F Pull out the outer race of the needle roller bearing with puller BMW No 00 8 573 and threaded spindle extension BMW No 00 8 575 Installing needle roller bearing for input bevel pinion Heat the needle roller bearing seat to 100 C 212 F Press in needle roller bearing using dr...

Page 194: ...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 Heat ball thrust bearing 5 to 100 C 212 F and push fully on to input bevel pinion Allow input bevel pinion to cool down C KR330131 3 5 4 1 2 h 100 h 100 ...

Page 195: ...ed ring 6 with Hylomar SQ 32 M Tighten threaded ring with pin wrench BMW No 33 1 700 Place thrust ring 7 in position L Note Ensure that the lip of the shaft seal is perfectly aligned on the thrust ring Tighten hex nut 8 with 36 mm 1 42 in socket wrench insert and reducing adapter BMW No 33 1 720 eCaution Nut must not damage shaft sealing ring X Tightening torque Threaded ring thread cleaned Hyloma...

Page 196: ...Heat housing cover to 100 C 212 F and pull it off Force shaft seal 4 out of housing cover with drift 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 3 2 4 h 100 C330022 1 33 1 830 KR33018 33 1 307 ...

Page 197: ...ndle BMW No 00 5 500 Check that outer race is correctly seated by striking gently L Note If new parts are installed e g taper roller bearing check tooth backlash and adjust if necessary Place the existing spacer ring 1 on the crown wheel Heat taper roller bearing 2 to 80 C 176 F and push it on Install crown wheel 3 Heat deep groove ball bearing 4 to 80 C 176 F and place it in position KR333019 00 ...

Page 198: ... hand press the crown wheel into the housing and turn to and fro to check tooth backlash L Note Check tooth backlash at three points 120 degrees apart turn the bevel pinion with the crown wheel Compensate for excessive backlash by inserting a thinner shim washer and for insufficient back lash by inserting a thicker shim washer 1 Backlash adjust without oil 0 07 0 16 mm 0 0027 0 0063 in 33 2 604 C3...

Page 199: ...l press into housing with the palm of the hands and turn to and fro If the correct spacer disc is installed the follow ing contact pattern appears with no load applied L Note The contact point is central on front flank V The contact point is closer to the larger diameter on back flank R eCaution Teeth should never make contact at the smaller di ameter If this contact pattern is obtained a thinner ...

Page 200: ...elected shim washer and install it Preload 0 05 0 1 mm 0 0020 0 0039 in Installing housing cover Lightly oil the lip and outer edge of the sealing ring Using drift BMW No 33 1 870 and handle BMW No 00 5 500 drive in the sealing ring Install O ring and apply a light coat of oil grease Heat housing cover to 80 C 176 F install Tighten retaining bolts in a crosswise pattern X Tightening torque Housing...

Page 201: ... arm bearing cap using two screwdrivers in the holes Loosen the free swinging arm bearing journal 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 swinging arm bearing journal Remove the swinging arm bearing journal A A C330014 C330030 00 8 581 C330040 00 8 582 ...

Page 202: ... arm When installing coat inner and outer sealing lips arrows with Staburags NBU 30 PTM eCaution Drive shaft clearance when suspension is com pressed aperture in retaining ring must be horizontal Removing drive shaft Press off drive shaft eCaution Avoid scratching painted parts use an underlay if necessary Checking universal joint for wear Determine end float and face runout Installing drive shaft...

Page 203: ...g journal 2 Tighten fixed bearing journal Tighten free bearing journal Tighten locknut 3 Install the left swinging arm bearing cap eCaution Make sure that the O ring is in good condition The drain hole must point down Secure suspension strut 1 X Tightening torque Fixed bearing journal 10 Nm Free bearing journal 7 Nm Locknut 160 Nm Suspension strut to swinging arm 50 Nm A A C330014 2 3 1 ...

Page 204: ...ad on oil filler plug Initial filling app 0 20 l 0 35 Imp pint 0 21 US quart During oil changes app 0 18 l 0 32 Imp pint 0 19 US quart Oil grade Brand name hypoid gear oil SAE 90 API class GL 5 ABS Install the brake disc in the previously marked position Install the rear wheel Install brake caliper eCaution Do not damage brake pads do not tilt when install ing Install speedometer signal transmitte...

Page 205: ...33 19 Removing and installing suspension strut L Note To remove the suspension strut support the rear axle X Tightening torque Suspension strut to swinging arm rear frame 50 Nm ...

Page 206: ...33 20 ...

Page 207: ...r 8 Removing and installing front brake disc 9 Removing installing rear brake disc 10 Removing and installing front ABS sensor 11 Adjusting front ABS sensor gap 12 Marking sensor wheel 12 Checking and adjusting sensor gap 12 Removing and installing rear ABS sensor 13 Adjusting rear ABS sensor gap 14 Marking sensor wheel 14 Checking and adjusting sensor gap 14 Removing and installing rear brake mas...

Page 208: ...g 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 Removing and installing front brake line 20 Removing and installing rear brake line 21 ...

Page 209: ...ake pad surface area cm2 sq in 100 15 5 Piston dia in brake caliper mm in 32 34 1 26 1 34 Piston diameter in handlebar lever cylinder mm in 20 0 79 Sensor gap front mm in 0 45 0 55 0 020 0 022 Brake pad Semi metallic Rear wheel Brake disc dia mm in 285 11 22 Brake disc thickness mm in 5 0 0 20 Minimum thickness mm in 4 5 0 18 Permissible lateral runout mm in 0 20 0 008 Brake pad surface area cm2 s...

Page 210: ...34 4 ...

Page 211: ...r Force back the brake pads pistons arrows Carefully remove the brake caliper eCaution Do not damage brake pads Install by following the above work instructions in the reverse order Force back the brake pads pistons Fill bleed the brake system eCaution Use new sealing rings 2 Do not damage brake pads X Tightening torque Brake caliper at fork slider tube 40 Nm Brake hose to brake caliper 15 Nm Blee...

Page 212: ...s out brake pistons 2 using a compressed air gun at the brake line connection eCaution Do not allow your fingers to become trapped be tween the pistons risk of injury Remove the two sealing rings 3 4 from the left right brake cylinder bores Examine the brake caliper pistons for damage Assembling front brake caliper Coat new sealing rings 3 4 with brake fluid and install Coat brake caliper pistons ...

Page 213: ...screw the brake caliper Install by following the above work instructions in the reverse order Force back the brake pads pistons Fill bleed the brake system To bleed release the brake caliper and position it with the bleed nipple at the highest point eCaution Renew sealing rings for brake line Do not damage brake pads X Tightening torque Brake caliper to rear wheel drive 40 Nm Brake hose to brake c...

Page 214: ...of injury Remove sealing rings 4 from left right cylinder Inspect the brake caliper piston for hairline cracks score marks other damage Assembling rear brake caliper Coat the new sealing rings with brake fluid and insert them into the left right brake caliper cylin ders Coat both brake caliper pistons with brake fluid and install them eCaution Do not tilt the brake pistons when installing Coat the...

Page 215: ... disc Degrease brake discs before installing L Note Installed direction arrow of brake discs must be correct X Tightening torque clean thread Loctite 243 24 Nm eCaution Check adjust the sensor gap Sensor gap 0 45 0 55 mm 1 77 2 22 in C360020 ...

Page 216: ...nged Install by following the above work instructions in the reverse order Degrease the brake disc before installing eCaution ABS Check sensor gap and adjust with spacing plates if necessary ABS If the brake disc and therefore the sensor wheel are renewed the disc s lateral runout must be determined marked Sensor gap 0 45 0 55 mm 1 77 2 22 in X Tightening torque Brake disc to rear wheel drive clea...

Page 217: ...r line Remove sensor 2 with Torx T 25 Install by following the above work instructions in the reverse order eCaution Run the sensor line correctly Check sensor gap and adjust if necessary with spacer plate 3 Sensor gap 0 45 0 55 mm 1 77 2 22 in X Tightening torque Sensor handtight 4 Nm C340050 1 3 2 ...

Page 218: ...ut over the entire circumfer ence Using a paint pencil make a permanent mark at the point where the sensor is farthest away from the sensor wheel arrow Checking and adjusting sensor gap Check adjust at the marked point If necessary remove install sensor with Torx T 25 and adjust sensor gap with spacing plates Sensor gap 0 45 0 55 mm 1 77 2 22 in eCaution After adjusting check that the sensor can m...

Page 219: ...he sensor bore Using Torx T 25 detach sensor 1 Separate plug connector 2 in the sensor line Install by following the above work instructions in the reverse order Coat O rings with oil before installing eCaution Run the sensor line correctly Check sensor gap and adjust if necessary with spacer plates 3 Sensor gap 0 45 0 55 mm 1 77 2 22 in X Tightening torque Sensor handtight 4 Nm C340070 3 1 2 ...

Page 220: ...the sensor wheel is farthest away from the sensor arrow eCaution If parts are replaced brake disc etc and a used or previously marked sensor wheel is installed the sensor ring must be measured and marked again Remove the old marking Checking and adjusting sensor gap Check adjust at the marked point If necessary remove install sensor with Torx T 25 and adjust sensor gap with spacing plates eCaution...

Page 221: ...ing and adjusting relief clearance of piston rod Insert a feeler gauge of the correct thickness be tween the adjusting screw brake lever and the stop arrow Feeler gauge thickness 0 2 mm 0 008 in Release locknut 1 Insert piston rod 2 turning to right until clear ance is present Turn the piston rod carefully to the left to with draw it again until no clearance is present lock it in this position Tig...

Page 222: ...ctions must be protected against dirt penetration if ncessary seal cover over Hold the front brake lever against the handlebar grip with a rubber band to close the brake fluid feed bore eCaution Switch off ignition disconnect and insulate the ground earth strap Remove cover 2 from ABS control unit press the lock in with a screwdriver and pull the cover up Detach wires 3 Pull off 2 pin plug 4 Pull ...

Page 223: ...he threaded pins with the crimp at the front Press the two cables into the remaining free ca ble entries Tighten the nuts eCaution Always use new self locking nuts X Tightening torque Battery M5 3 5 Nm Battery M4 3 Nm Install a new cover eCaution When sliding the cover on make sure that all cables are correctly located in their cable entries Scrap the old cover Screw ABS brake lines 1 to ABS unit ...

Page 224: ...nd press the two wires into the center smaller cable en tries Push the two plugs for the connecting cable wir ing harness onto the threaded pins with the crimp at the front Press the two cables into the remaining free ca ble entries Tighten the nuts eCaution Always use new self locking nuts Install a new cover 1 eCaution When sliding the cover on make sure that all cables are correctly located in ...

Page 225: ...the red engine cable using the Torx screw Use the second Torx screw to secure the flat plug to the relay Press the contact interlock into the relay base at the side Push the relay base into the relay housing at the same time pressing both engine cables into the left cable entries on the relay housing red at bot tom black at top Attach black engine cable to left threaded pin M5 with crimp at back e...

Page 226: ...34 20 Removing and installing brake lines Removing and installing front brake line C340020 ...

Page 227: ...34 21 Removing and installing rear brake line C340030 ...

Page 228: ...ructions in the reverse order eCaution Renew sealing rings for brake line Attach brake line to master cylinder so that it cannot become kinked or abraded when the handlebar is turned Fill bleed the brake system X Tightening torque Brake hose and brake line 15 Nm Bleed screws in front brake caliper 7 Nm Bleed screw on rear brake caliper 4 Nm Bleed screw on ABS unit 9 Nm Junction block at front fram...

Page 229: ...el 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 11 Centering the wheel rim 11 Centering lateral runout 11 36 Wheels and tyres ...

Page 230: ...36 2 ...

Page 231: ...al 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 Front bar psi 2 2 31 9 Rear bar psi 2 5 36 3 With pillion passenger Front bar psi 2 5 36 3 Rear bar psi 2 7 42 0 With pillion passenger and luggage Front bar psi 2 5 36 3 Rear bar psi 2 9 45 1 ...

Page 232: ...36 4 ...

Page 233: ... 4 and front wheel Installing front wheel Install front wheel and spacing bushings Apply a light coating of Molykote paste to the quick release axle install it Tighten the retaining screw 1 Install the brake calipers Compress the front fork firmly several times Tighten the clamp screws 2 ABS Check sensor gap and adjust if necessary ABS sensor gap 0 45 0 55 mm 1 77 2 22 in X Tightening torque Quick...

Page 234: ...ight and the claws of the internal puller Heat bearing seat to 80 C 176 F Pull out the wheel bearing with counter support 22 1 BMW No 00 8 572 and internal puller 21 4 BMW No 00 8 573 Press out spacing bushing 1 and wheel bear ing 2 with drift BMW No 36 5 530 Degrease bearing seats Heat bearing seat to 80 C 176 F First insert wide bearing using drift BMW No 36 5 512 and handle BMW No 00 5 500 C360...

Page 235: ...ntact Install spacer tube 2 Bearing seat temperature 80 C 176 F Insert narrow bearing 3 with drift BMW No 36 5 512 and handle BMW No 00 5 500 Install circlip with convex side facing down Drive in shaft sealing ring with drift BMW No 36 5 513 36 5 513 C360040 00 5 500 36 5 512 3 2 1 h 100 36 5 513 C360030 ...

Page 236: ...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 X Tightening torque Screw in wheel studs handtight then tighten them in a crosswise pattern Initial tightening 50 Nm Final tightening 105 Nm 00 1 550 C360010 ...

Page 237: ... the balancing shaft Align the balancing fixture BMW No 36 3 600 with knurled screws and bubble gauge 5 6 Allow wheel to settle Clean points of adhesion for balance weights Attach adhesive weights 7 opposite the heavi est point on both sides of the wheel rim with the total weight equally divided between the left and right sides eCaution Maximum balancing weight 60 g 2 12 oz Repeat the balancing pr...

Page 238: ...5 BMW No 36 3 613 on the centering collar side with the wheel studs then install the balancing shaft Clamp locating discs 6 BMW No 36 3 615 to the balancing shaft at left and right in such a way that the shaft cannot wander Align the balancing fixture BMW No 36 3 600 with the knurled screws bubble gauge 7 8 Check radial axial runout eCaution Only apply dial gauge to machined inner face of wheel ri...

Page 239: ...tightened on the side directly opposite the larg est deviation Remove grub screw from relevant spoke nipple before tightening Working forwards and backwards from the max imum and minimum value points take up slack at every third spoke nipple eCaution Never attempt to compensate for the entire horizon tal runout at only one or two spokes At the point where the maximum plus and minus values occur ta...

Page 240: ...36 12 ...

Page 241: ...udguard 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 11 46 Frame ...

Page 242: ...46 2 ...

Page 243: ...ht of seat at unladen weight mm in 740 29 1 Wheelbase in normal load position mm in 1650 65 0 Ground clearance at unladen weight mm in 172 6 77 Caster angle in normal load position mm in 86 3 36 Steering head angle in normal load position 60 5 Max wheel track offset mm in 9 0 35 Unladen weight ready for road full tank kg lbs 256 564 Axle load distribution without rider front rear kg lbs 126 130 27...

Page 244: ...46 4 ...

Page 245: ...crews 1 Remove the nuts at the rubber cover 2 eCaution The locking lug 3 of the retaining elements must engage in the hole If necessary bend the retaining element Removing installing front mudguard X Tightening torque Mudguard to slider tube bridge 8 Nm C460020 1 3 2 CUB0050 ...

Page 246: ...ch the engine holder Heat the ball joint mount at the leading link to max 120 C 248 F and detach it eCaution Avoid scratching the leading link Pull the leading link off its pivots and pull the tel escopic fork forwards Remove the suspension strut mount trim panel upwards Remove suspension strut Remove headlight Unplug and remove the flashing turn indicators Remove handlebar Loosen screw for cap at...

Page 247: ...ve frame L Note Only loosen the threaded connections at the lower rear frame Install by following the above work instructions in the reverse order X Tightening torque Fork bridge to frame clean thread Loctite 243 130 Nm Threaded connections between frame and engine Front 82 Nm Rear 58 Nm ...

Page 248: ...r wheel Detach rear brake caliper Detach ABS sensor Detach speedometer signal transmitter Detach brake line cover on swinging arm Tie the swinging arm up to the frame with a strap Remove suspension strut L Note Press to the rear at the top Pull the swinging arm up with the strap Remove silencer muffler L Note Alternately strike the silencer muffler rearwards with the palm of the hand or pull it Di...

Page 249: ...lug Detach the gear lever Separate the throttle potentiometer and throttle positioner plugs at the left plug retaining plate Detach both fuse boxes at the plug retaining plate Separate the side prop stand switch plug Separate the neutral indicator switch plug Detach the left plug retaining plate Remove the injectors Pull off the injector line plugs Detach the breather hose at the air cleaner cas i...

Page 250: ...m Brake pedal to footrest assembly 37 Nm Removing and installing side prop stand Remove keeper 1 from side prop stand switch Pull off side prop stand switch 2 Disconnect tension springs Remove side prop stand eCaution Note wiring paths Lubricant e g Staburags NBU 30 PTM X Tightening torque Side stand to pivot mount clean thread Loctite 243 42 Nm C460040 C460050 2 1 ...

Page 251: ...de freely up to the motorcycle Adjust measuring stops arrows until they con tact the rim not the tyre Attach hook 2 to wheel spoke to secure the gauge firmly to the wheel Align front wheel parallel with the gauge Measure distance between outer edge of gauge and wheel rim using depth gauge 3 or ruler and make a note of the dimension Calculate wheel track offset S Wheel track offset S is the distanc...

Page 252: ...g 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 Track offset S S S 122 5 mm 124 5 mm 4 82 in 4 92 in Track offset S 2 0 mm 0 10 in A Fh 2 B Fv 2 Fh 2 Fv 2 A Fh 2 B Fv 2 ...

Page 253: ...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 Equipment ...

Page 254: ...51 2 ...

Page 255: ...Serrated screws thread cleaned Loctite 270 15 Nm Removing and installing ignition light switch Remove socket head cap screw 2 Removing and installing lock barrel Key in ON position press in keeper 1 with a stiff wire or similar Pull out lock barrel with key Lubricate the new lock barrel with Shell Retinax A Insert the lock barrel with the key in the ON posi tion Press lock barrel down until keeper...

Page 256: ... re tainer 2 Pull out lock barrel with key Lubricate the new lock barrel with Shell Retinax A Install lock barrel with key at a right angle to di rection of travel Install by following the above work instructions in the reverse order Drilling out lock barrel Use a 4 5 mm 0 16 0 20 in dia drill bit to drill the full length of the lock barrel Repeat with a drill bit of larger diameter until the lock...

Page 257: ...52 1 Contents Page 52 Removing and installing seat 3 52 Seat ...

Page 258: ...52 2 ...

Page 259: ...52 3 52 Removing and installing seat Take out screw 1 for seat back Pull out the locking pin and take off the seat back C520010 C520020 1 ...

Page 260: ...52 4 ...

Page 261: ...ng 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 General electrical equipment ...

Page 262: ...61 2 ...

Page 263: ...61 3 61 Technical data R 850 C R 1200 C Battery Amp h 19 ...

Page 264: ...61 4 ...

Page 265: ...isconnect earth ground lead from battery Insulate earth ground lead Detach the central electrical equipment box If necessary detach the complete wiring harness and remove it with the central electrical equip ment box Install by following the above work instructions in the reverse order C610020 ...

Page 266: ... 8 Fuel pump relay 9 Horn relay 10 Load relief relay 11 Fuse Connections to fuses No 1 on left looking forwards 1 Instrument cluster brake and rear lights 15 Amp 2 Parking light 15 Amp 3 Flashing turn indicators clock 15 Amp 4 Power socket 15 Amp 5 Motronic 15 Amp 6 Fuel pump 15 Amp 7 Heated handlebar grips 4 Amp 8 Spare fuse 4 Amp 9 Spare fuse 15 Amp 10 Spare fuse 15 Amp C610010 3 6 4 5 7 8 9 10 ...

Page 267: ... 80 Ω Run wiring without kinking and avoid risk of abra sion Note the number and position of the cable straps Apply a thin coating of contact grease e g CENTOPLEX 3 CU to the central earth ground point which must be cleaned to bright metal first L Note When removing the wiring harness take out the central electrical equipment box at the same time X Tightening torque Ground earth connection to engi...

Page 268: ...61 8 Wiring harness View from left C619020 1 2 3 ...

Page 269: ...61 9 1 C619021 ...

Page 270: ...61 10 2 C619022 ...

Page 271: ...61 11 3 C619023 ...

Page 272: ...61 12 Wiring harness View from right 1 2 3 C619030 ...

Page 273: ...61 13 1 C619011 ...

Page 274: ...61 14 2 C619012 ...

Page 275: ...61 15 3 C619013 ...

Page 276: ...61 16 ...

Page 277: ...62 1 Contents Page 62 Technical data 3 Removing and installing instrument cluster 5 Dismantling and assembling instrument cluster 5 62 Instruments ...

Page 278: ...62 2 ...

Page 279: ...62 3 62 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 ...

Page 280: ...62 4 ...

Page 281: ...parate 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 C620010 ...

Page 282: ...62 6 ...

Page 283: ...63 1 Contents Page 63 Technical data 3 Removing and installing headlight 5 Adjusting headlight 5 63 Lights ...

Page 284: ...63 2 ...

Page 285: ...hnical 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 ...

Page 286: ...63 4 ...

Page 287: ... 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 Adjustment distance 15 cm 5 90 in at a distance of 10 m 32 8 ft ...

Page 288: ...63 6 ...