Page 2 - Introduction
Introduction This repair manual will help you to perform all the main maintenance and repair work correctly and efficient-ly. It should be consulted regularly by workshop personnel as an addition to the practical and theoretical knowledge obtained in Training School courses. It is a contribution tow...
Page 3 - Change the brake fluid annually
Order No. 01 71 0 008 872 UX-VS-2, 06.99 Printed in Germany Customer Licence plate No. Order No. Mechanic’s signature BM W In sp e c tio n a t 1 0 00 km (6 0 0 mi le s) BM W S e rvi c e ev er y 10 0 0 0 km (6 00 0 mi le s) BM W In sp e c tio n ev er y 20 00 0 k m (1 2 0 0 0 mi le s) BM W A n n ual S...
Page 5 - Contents
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 Contents Group / Chapter
Page 7 - Page; 0 Maintenance and general instructions
00.1 Contents Page 00 Tightening torques ......................................................................................................................3 Table of operating fluids ...........................................................................................................9 Key ...
Page 9 - Tightening torques
00.3 00 Tightening torques Model R 850/1200 C Connection Nm 11 Engine Cylinder head Tightening sequence: 1. Tighten cylinder head nuts (oiled) crosswise 1.1 Tighten all nuts to correct torque for joint 20 1.2 Tighten all nuts to correct angle 90° 1.3 Tighten all nuts to correct angle 90° 2. M 10 bol...
Page 15 - Table of operating fluids
00.9 Table of operating fluids Item Use Order number Quantity Lubricant Optimoly MP 3 High-performance lubricating paste 07 55 9 062 476 100 g tube Optimoly TA High-temperature assembly paste 18 21 9 062 599 100 g tube Silicone grease 300, heavy Damping grease 07 58 9 058 193 10 g tube Retinax EP2 W...
Page 17 - Key to maintenance intervals; II; Reading out MoDiTeC fault memory
00.11 Key to maintenance intervals – BMW Inspection 1000 km/600 miles I – BMW Service II – BMW Inspection III – BMW Annual Service IV Reading out MoDiTeC fault memory (Inspections I, II, III and IV) • Remove the left air cleaner trim panel. • Connect MoDiTeC to diagnostic plug. • Read out the fault ...
Page 18 - Fill quantity for engine:
00.12 Changing engine oil, renew oil filter element (Inspections I, II, III and IV) L Note: If the motorcycle is ridden only for short distances or outside temperatures are below 0°C (32°F): change the oil and renew the oil filter element every 3 months, but at least every 3 000 km (1 800 miles). • ...
Page 19 - Changing oil in gearbox; Oil grade for gearbox:; Oil grade for rear wheel drive:
00.13 Changing oil in gearbox (Inspections III and IV)or at least every 2 years • Change the gearbox oil while at regular operating temperature. • Loosen clip/trim (1) at right silencer and turn downwards. • Take out oil filler plug (3) and oil drain plug (2) and allow the oil to drain out. • Clean ...
Page 20 - Renewing fuel filter
00.14 Renewing fuel filter (Inspection III)In normal operating conditions every 40 000 km (24 000 miles); if fuel quality is poor every 20 000 km (12 000 miles) • Remove seat. • Remove right air cleaner trim panel. • Remove left and right trim panels. e Caution: Fuel is flammable and a hazard to hea...
Page 23 - Renewing Poly-V belt; no tools to be used
00.17 Renewing Poly-V belt (every 60 000 km/36 000 miles) (Inspection III) • Remove the cover. • Use the spark plug cap assembly tool from the toolkit to pull off the spark plug caps. • Use spark plug wrench, BMW No. 12 3 510 , to unscrew and remove the spark plugs. • Remove the horn with its mount....
Page 24 - Checking brake fluid level; Brake fluid grade
00.18 Checking brake system for correct operation and freedom from leaks; repairing/renewing if necessary (Inspection III) • Checking brake system for leaks. Checking brake fluid level L Note: The brake fluid volume (between MIN and MAX) is sufficient for the complete range of pad wear from new to t...
Page 25 - Checking front brake pad wear; Minimum lining thickness:; Checking rear brake pad wear
00.19 Checking brake pads and discs for wear/renewing (Inspections II and III) Checking front brake pad wear • Examine the wear limit marks (arrows). e Caution: Brake pad thickness must not fall below the minimum value.Change pads only as a complete set. Minimum lining thickness: .......... 1.5 mm (...
Page 32 - Tightening cylinder heads; Top dead centre on ignition stroke:; Tightening procedure after 1 000 km (600 miles)
00.26 Tightening cylinder heads (Inspection I) • Remove cylinder head cover. e Caution: Trap escaping oil. • Select a gear and turn the rear wheel, or set the piston to TDC on the ignition stroke by turning the belt pulley. Top dead centre on ignition stroke: • The OT (TDC) mark is visible and the i...
Page 33 - Checking/renewing spark plugs; Gap wear limit; Check synchronising; BMW; MoDiTeC
00.27 Checking/renewing spark plugs (Inspection II)/renewing (Inspection III) • Unscrew and remove spark plugs with the spark plug wrench, BMW No. 12 3 510 . e Caution: Do not bend electrodes - risk of breakage! Electrode gap: .......................... 0.8 mm (0.031 in) Gap wear limit :...............
Page 36 - Assembling engine
11.2 Contents Page Removing alternator mount cover .........................................................................................33 Renewing radial shaft seal in alternator mount cover ...................................................34 Renewing radial shaft seal for rotary breather ......
Page 37 - Installing engine
11.3 Installing right cylinder head ....................................................................................................57 Adjustment specification ...................................................................................................................57 Installing left cy...
Page 45 - Sectioned drawing of engine
Page 46 - Lubricating oil circuit
Page 47 - Coolant circuit
Page 49 - Removing engine
11.15 Removing engine L Note: Auxiliary shaft, timing chains, chain tensioner/guide rails and crankshaft can only be dismantled after the engine has been removed. All other components can be dismantled while the engine is still installed. • Drain engine oil. • Drain the brake system completely. • Dr...
Page 52 - Dismantling engine
11.18 Dismantling engine • Attach engine mount, BMW No. 11 0 630 , to the engine block. • Transfer engine to assembly frame. • Drain engine oil. • Remove the oil filter, using oil filter wrench, BMW No. 11 4 650 . 00 0 630 RS110010 11 4 650 RS110950
Page 53 - Removing cylinder head cover
11.19 Removing cylinder head cover • Unscrew and remove spark plug with the spark plug wrench, BMW No. 12 3 510 . • Remove cylinder head cover. e Caution: Trap escaping oil. 12 3 510 RS110020
Page 56 - Removing valve gear holder
11.22 Removing valve gear holder • Remove camshaft sprocket cover. • Unscrew/press off camshaft sprocket. L Note: If the camshaft sprocket (1) is not removed after loosening, it must be held firmly and prevented from falling into the engine block (e.g. with a cable strap). • Remove valve gear holder...
Page 59 - Removing cylinder head
11.25 Removing cylinder head RS110110 M6 x 30 M6 x 30 M6 x 30 M10 x 70
Page 60 - Removing and installing valves; Removing valve stem seals
11.26 Dismantling, checking, repairing and re-assembling cylinder head Removing and installing valves e Caution: Do not scratch sealing face on cylinder head. Place the head on a clean, scratch-free surface. • Attach valve spring tensioner, BMW No. 11 5 690 , to cylinder head. • Clamp the valve spri...
Page 61 - Checking valves for wear; Remachining valve seat
11.27 Checking valves for wear • Clean combustion residue from valves. • Check valve dimensions. a ............................................ See Technical data Remachining valve seat e Caution: Width (B) and diameter (D) must always be main-tained when remachining the valve seat. a .................
Page 63 - Installing valve and valve stem seal
11.29 Installing valve and valve stem seal L Note: If a valve was removed, the valve stem seal must be renewed. • Oil the stem when installing the valve. • Shrink a short length of tube (arrow) on to the end of the valve stem. • Install the valve stem seal with a 5 mm (0.20 in) dia. drift, BMW No. 1...
Page 65 - Checking pistons and cylinders; Assembling pistons
11.31 Checking pistons and cylinders Reference temperature for measurements: ...... 20 ° C (68 ° F) • Measure cylinder bore with internal probe at 20 mm (0.79 in) and 100 mm (3.94 in) from the top in direction of piston pin, and again at a right angle to the first measurement. a .......................
Page 66 - Removing/installing conrod; Installed direction of conrods:
11.32 Removing/installing conrod • Turn crankshaft to TDC position. • Lock the clutch housing with special tool BMW No. 11 5 640 . • Remove conrod. L Note: Conrods can also be removed/installed with the crankshaft removed. e Caution: Do not accidentally interchange conrods or bearing shells. • Insta...
Page 67 - Removing alternator mount cover
11.33 Removing and installing alternator cover with engine installed e Caution: Disconnect earth (ground) lead from battery. Insulate earth (ground) lead. • Detach the horn. • Remove the oil cooler line. • Separate the Hall-effect signal transmitter plug. • Remove the starter motor. • Remove rear le...
Page 69 - Removing auxiliary shaft drive
11.35 Removing auxiliary shaft drive • Align markings (arrows) on timing pinion and chain sprocket. • Unscrew and remove cooling oil pipe (1)/swing the pipe forwards. • Remove chain tensioner (2). • Remove chain tensioning rail (3). • Remove chain guide rail (4). • Lock clutch housing with special t...
Page 70 - Removing oil pump
11.36 Removing oil pump • Remove oil pump cover (1). • Remove complete oil pump (2) together with cooling oil pipe (3), and dismantle. e Caution: Check installed positions of parts which have al-ready been run together. RS110410 M6 x 45 M6 x 50 M6 x 45 M6 x 45 M6 x 50 3 1 2
Page 72 - Dismantling crankcase
11.38 Dismantling crankcase • Turn engine on to its side. • Remove screws on right side. RS110261 M1 0 x 1 0 0 ‹ M1 0 x 10 0 ‹ M8 x 8 0 M8 x 8 0 M8 x 3 5 M8 x 3 5
Page 75 - Checking conrods
11.41 Removing and installing oil pick-up basket X Tightening torque: M 6 screw ...................................................... 9 Nm e Caution: Make sure that the O-ring is not omitted, and is in-stalled undamaged. Replacing oil level sight glass • Pierce the plastic disc with a large screwdr...
Page 76 - Measuring radial bearing play
11.42 Measuring main and big end bearing play Measuring radial bearing play • Measure main bearing journal with an external micrometer crosswise in two planes, A and B. • Enter measured values on record sheet. a ............................................ See Technical data e Caution: The crankshaf...
Page 77 - Installing main bearing; Measuring axial bearing play
11.43 Installing main bearing • Insert tensioner rail/slide rail pivot pin (1) for centering purposes. • Tighten M8 and M10 housing screws. X Tightening torque/tightening order: 1. M 10 screw (oiled) .................................... 45 Nm2. M 8 screw (oiled) ........................................
Page 78 - Measuring big end bearing play
11.44 Measuring big end bearing play • Measure crankpin with an external micrometer in the thrust direction and offset through 90 o . • Install bearing shells and assemble conrods. • Using tightening angle gauge, BMW No. 11 2 210 , tighten the big end bolt. X Tightening torque: Big end bolts oiledJo...
Page 79 - Installing conrod
11.45 Assembling engine Installing conrod • Clamp crankshaft in a vise provided with protec-tive jaws. • Oil the big end bolts, screw them in by hand and tighten with angle gauge, BMW No. 11 2 210 . e Caution: Oil the bearings. Do not accidentally confuse conrods or bearing shells. Always use new bi...
Page 81 - Assembling engine block
11.47 Assembling engine block • Coat clean, grease-free sealing faces (arrow) with 3-Bond 1209 . • Secure the timing chain with rubber band (1) to the timing chain tensioning and slide rail. RS110920 M1 0 x 10 0‹ M1 0 x 10 0‹ M6 x 5 0 M6 x 5 0 M6 x 5 0 M6 x 5 0 M6 x 50 M6 x 50 M6 x 5 0 M6 x 5 0 M6 x...
Page 83 - Installing the crankshaft radial seal
11.49 Installing the crankshaft radial seal • Pre-form the lip of the radial shaft seal carefuilly by hand (1). • Oil the radial shaft seal at the sealing/contact surface. • Place radial seal over sliding sleeve (2)/remove sliding sleeve (3). • Drive the radial shaft seal in with handle, BMW No. 00 ...
Page 84 - Installing clutch housing
11.50 Installing clutch housing e Caution: Always use new bolts for housing and cover. • Install clutch housing with mark (1) aligned with crankshaft mark (2). • Lock the clutch housing with special tool BMW No. 11 5 640 . • Insert all screws by hand and tighten down. X Tightening torque: Clutch hou...
Page 85 - Installing oil pump
11.51 Installing oil pump e Caution: Oil the sliding-contact faces. • Install outer rotor (1) of oil pump in pump hous-ing. • Install oil pump housing with cooling oil pipe (2). e Caution: O-ring (3) must be in good condition. • Install Woodruff key (4), outer rotor (5) and inner rotor (6) in coolin...
Page 86 - Installing auxiliary shaft drive
11.52 Installing auxiliary shaft drive • Set crankshaft mark against mark on auxiliary shaft. e Caution: Adjust according to the adjusting instructions. a ............................ See “Installing cylinder head”. • Lock the clutch housing with special tool BMW No. 11 5 640 . • Install chain sproc...
Page 87 - Installing piston; Piston size identification:
11.53 Installing piston • Turn joint in oil scraper ring (arrow) so that it fac-es upwards. • Install piston ring gap offset by 120° in each case. Production locating point X = install on exhaust side. e Caution: Ensure that retaining rings are properly seated on piston pin. Oil the sliding-contact ...
Page 88 - Installing cylinder
11.54 Installing cylinder • Apply 3-Bond 1209 to the cylinder base sealing face (arrow), which must be clean and free from grease. • Oil the cylinder wall. • Compress the piston rings with a clamping strap, BMW No. 11 2 900 . • Install the cylinder and at the same time pass the timing chain and the ...
Page 89 - Installing cylinder head
11.55 Installing cylinder head • Install cylinder head gasket. • Fit cylinder head/insert correctly positioned cam-shaft chain sprocket (1) and timing chain into chain cavity. • Install valve gear support (2). • Tighten cylinder head down. e Caution: Install collar (arrow) of cylinder head nut towar...
Page 90 - Adjusting valve clearances
11.56 Adjusting valve clearances • Set piston to TDC on the ignition stroke. • Measure valve clearance with feeler gauge. • Correct valve clearance with adjusting screw and lock into position. Valve clearances with engine cold(max. 35 ° C/95 ° F): Inlet ........................................... 0....
Page 91 - Installing right cylinder head; Adjustment specification
11.57 Installing right cylinder head Adjustment specification e Caution: When assembling, always start with the right cylin- der. Right cylinder = at TDC on ignition stroke:marks (arrows) on chainwheel/auxiliary shaft and chain sprocket/crankshaft are aligned. • Locate ignition-stroke TDC with inser...
Page 92 - Installing left cylinder head
11.58 Installing left cylinder head Adjustment specification e Caution: When installing, always begin with the right cylin- der. Left cylinder = TDC on ignition stroke: marks (ar-rows) on chain sprocket/auxiliary shaft and chain-wheel/crankshaft face down • Locate ignition-stroke TDC with insert pin...
Page 94 - Installing alternator mount cover; Installing magnetic gate/belt pulley; Loctite instant
11.60 Installing alternator mount cover • Place sliding sleeve, BMW No. 11 5 680 , on crankshaft. • Apply 3-Bond 1209 to the sealing face (arrow), which must be clean and free from grease. • Install alternator mount cover. X Tightening torque: M 8 screw .................................................
Page 95 - Timing the ignition; BMW MoDiTeC
11.61 Timing the ignition • Using TDC locating pin, BMW No. 11 2 650 , lock the clutch housing. • Connect BMW MoDiTeC with adapter cable to Hall-effect gate plate. • Adjust in accordance with tester guidance. • Remove the TDC locating pin. 11 2 650 RS110461
Page 96 - Installing alternator
11.62 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 adjustin...
Page 99 - 2 Engine electrics
12.1 Contents Page 12 Technical data ................................................................................................................................3 Removing and installing coil and ignition lead ............................................................5 Check ignition coil resi...
Page 103 - Check ignition coil resistance
12.5 Removing and installing coil and ignition lead • Remove fuel tank. e Caution: Switch off ignition. Disconnect ground (earth) cable at battery and insulate it. • Pull off spark plug cap with special puller, BMW No. 12 3 520 . • Release threaded connection for central electri-cal equipment box. •...
Page 104 - Removing and installing alternator; using no tools
12.6 Removing and installing alternator • Remove seat. • Remove fuel tank. e Caution: Switch off ignition. Disconnect ground (earth) cable at battery and insulate it. • Remove horn with holder. • Remove front cover from engine. • Remove alternator retainers (1, 2, 3). • Remove rotary breather tube. ...
Page 105 - Checking alternator
12.7 Dismantling/reassembling alternator • Take out the cover retaining screws (1). • Release clips (2) and remove the cover. • Remove voltage regulator (3). • Remove the Poly-V belt pulley. • Install by following the above work instructions in the reverse order. X Tightening torque: Belt pulley at ...
Page 107 - Checking starter relay
12.9 Dismantling/reassembling starter motor • Detach lead (1). • Remove retaining screws (2). • Remove flange (3). • Remove solenoid switch (4) after taking out the retaining screws (5). • Remove release lever (6) and spring (7) from so-lenoid switch (8). • Remove retaining ring (9) and take starter...
Page 111 - 3 Fuel preparation and control
13.1 Contents Page 13 Technical data ................................................................................................................................3 Removing and installing air cleaner ...................................................................................5 Removing and...
Page 113 - Technical data
13.3 13 Technical data R 850 C R 1200 C Fuel grade Super (premium), unleaded, 95 octane (RON) Mixture preparation Motronic MA 2.4 Throttle stub pipe intl. dia. mm (in) 35 (1.38) Throttle angle in rest position depending on throttle positioner Air cleaner Flat-pattern paper element
Page 115 - Removing and installing air cleaner
13.5 Removing and installing air cleaner a See Group 46 (Removing/installing rear frame) Removing and installing throttle stub pipe • Remove throttle stub pipe (1). Removing and installing throttle potentiometer • Remove throttle potentiometer (2). • Adjusting throttle potentiometer with BMW MoDiTeC...
Page 116 - Removing and installing injectors
13.6 Removing and installing throttle positioner • Remove the throttle positioner (3). e Caution: The throttle positioner operates at the control unit voltage of 5 V. It must not be connected directly to the motorcycle’s electrical system. X Tightening torque: Throttle positioner retaining screw(cle...
Page 119 - Removing and installing fuel filter; 6 Fuel tank and lines
16.1 Contents Page 16 Technical data ................................................................................................................................3 Removing and installing fuel tank .......................................................................................5 Removing a...
Page 123 - Removing and installing fuel tank
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 125 - Checking fuel pump pressure
16.7 Removing and installing fuel pump and fuel level sensor • Detach the electrical connections at the fuel pump (4). • Release the hose clip at the fuel pump. • Remove fuel pump. • Install by following the above work instructions in the reverse order. • Secure non-reusable hose clips with pliers, ...
Page 127 - Removing and installing exhaust system; Removing and installing silencer (muffler); 8 Exhaust system
18.1 Contents Page 18 Removing and installing exhaust system ........................................................................3 Removing and installing silencer (muffler) ............................................................................3 Removing and installing front exhaust pipes ...
Page 131 - Removing clutch; Removing and installing clutch hydraulic line
21.1 Contents Page 21 Technical data ................................................................................................................................3 Removing and installing clutch ............................................................................................5 Removing...
Page 135 - Removing and installing clutch
21.5 Removing and installing clutch Removing clutch a Preparatory work is as for “Removinggearbox” (see Group 23) • Lock the clutch housing with special tool BMW No. 11 5 640 . • Remove the clutch. Installing clutch • Install clutch housing with mark (1) aligned with crankshaft mark (2). • Lock the ...
Page 137 - Filling/bleeding clutch line; not be below
21.7 Filling/bleeding clutch line e Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint. L Note: The description applies to a brake system filling and bleeding device with vacuum extraction of brake flu-id at the bleed line....
Page 145 - Renewing output shaft sealing ring
23.7 Renewing the shaft sealing rings in the gearbox housing and gearbox cover L Note: All shaft sealing rings can be renewed with the gear-box installed, apart from the input-side shaft sealing ring on the input shaft.If the gearbox is dismantled completely, all shaft sealing rings must be renewed....
Page 146 - Renewing input shaft sealing ring at output side; Renewing shaft sealing ring for selector drum
23.8 Renewing input shaft sealing ring at output side • Pierce the shaft sealing ring with piercing tool, BMW No. 00 8 583 . • Screw the pull rod, BMW No. 00 8 581 , into the pierced hole and use impact weight, BMW No. 00 8 582 , to remove the shaft sealing ring. • Install the new sealing ring with ...
Page 147 - Dismantling gearbox; Removing gearbox housing
23.9 Dismantling gearbox Removing gearbox housing • Take out oil filler/level check screw (2). • Take out oil drain plug (7) and drain the oil out of the gearbox into a suitable tray. • Remove breather (1). • Unclip cable (3) for neutral indicating switch (4). • Compress spring (5) and take off neut...
Page 148 - Removing selector drum; Dismantling/assembling selector shaft
23.10 Removing selector drum • Pull the selector shafts (1) out of the selector forks. • Swing the selector forks (3/8) out towards the edge of the cover (arrows). • Remove locking pin (9). • Press guide plate (5) in the opposite direction to the spring loading (arrow). • Swing locking lever (6) tow...
Page 149 - Removing gearbox shafts
23.11 Removing gearbox shafts • Remove breather tube (3). • Heat bearing points in gearbox cover to80 °C … 100 °C (176 °F ... 212 °F). • Take off input shaft (4), output shaft (1) and intermediate shaft (5) together from the cover. • Remove selector fork (2) from intermediate shaft. Renewing deep-gr...
Page 150 - Dismantling/assembling input shaft; Dismantling input shaft
23.12 Dismantling/assembling input shaft Dismantling input shaft • Clamp the input shaft into the vise, using soft jaws. • Use universal puller, BMW No. 00 7 500 , and pressure head (arrow) to pull off deep-groove ball bearing (9) with spacing washer (8). • Note the thickness of spacing washer (8). ...
