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BMW R 850 C R 1200 C Motorcycle Repair Manual – PDF DOWNLOAD
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BMW R 850 C R 1200 C Motorcycle Repair Manual – PDF DOWNLOAD
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Description
BMW R 850 C R 1200 C Motorcycle Repair Manual – PDF DOWNLOAD
DESCRIPTION:
BMW R 850 C R 1200 C Motorcycle Repair Manual – PDF DOWNLOAD
Introduction :
This Repair Manual will help you to perform all the main maintenance and repair work correctly and efficiently. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and practical knowledge acquired at the BMW Training Centre. It is a contribution toward achieving even higher Service quality. A new issue of this repair manual will be published if amendments or additions (supplements) are needed. All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification.
• The Repair Manual is structured in the logical sequence of the work to be performed: Removal, Disassembling, Repair, Assembly, Installation.
• Work to be performed during an Inspection is described in Group “00”. The various inspection routines are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that work can take place without interruption.
• Use of the BMW special tools needed for certain tasks is described in the work instructions.
• Use of the BMW special tools needed for certain tasks is described in the work instructions.
If the need arises, repair instructions are also issued in the form of Service Information. This information is of course incorporated into the next issue of the Repair Manual. We also recommend, as an additional source of information
TABLE OF CONTENTS:
BMW R 850 C R 1200 C Motorcycle Repair Manual – PDF DOWNLOAD
Repair Manual........................................................ 1 Introduction......................................................... 3 Maintenance schedule................................................. 5 Pre-delivery check................................................... 6 Contents............................................................. 7 00 Maintenance and general instructions.............................. 9 Tightening torques............................................... 11 Table of operating fluids........................................ 17 Key to maintenance intervals..................................... 19 Reading out MoDiTeC fault memory................................. 19 (Inspections I, II, III and IV).............................. 19 Checking throttle cable play, adjusting if necessa............... 19 (Inspections I and III)...................................... 19 Changing engine oil, renew oil filter element.................... 20 (Inspections I, II, III and IV).............................. 20 Changing oil in gearbox.......................................... 21 (Inspections III and IV)..................................... 21 or at least every 2 years.................................... 21 Changing oil in rear wheel drive; cleaning inducti............... 21 (Inspections I, III and IV).................................. 21 Every 40 000 km (24 000 miles) or at least every 2........... 21 Renewing fuel filter............................................. 22 (Inspection III)............................................. 22 In normal operating conditions every 40 000 km (24........... 22 Checking battery acid level/topping up if necessar............... 24 (Inspections III and IV)..................................... 24 Renewing intake air cleaner element.............................. 24 (Inspection III)............................................. 24 In very dirty and dusty operating conditions, rene........... 24 Renewing Poly-V belt............................................. 25 (every 60 000 km/36 000 miles)............................... 25 (Inspection III)............................................. 25 Poly-V belt adjusting procedure:............................. 25 Checking brake fluid level................................... 26 Front brake.............................................. 26 Rear brake............................................... 26 Checking brake pads and discs for wear/renewing.............. 27 (Inspections II and III)................................. 27 Checking front brake pad wear................................ 27 Checking rear brake pad wear................................. 27 Checking brake disc wear..................................... 27 Renewing brake pads Front brake.............................. 28 Renewing brake pads Rear brake............................... 28 Renewing brake fluid and bleeding brake system................... 29 Renew the brake fluid annually............................... 29 (Inspection IV).............................................. 29 [ABS Inspection II and III].................................. 29 Bleeding front brake circuit/renewing brake fluid............ 29 Additionally with [ABS].................................. 30 Bleeding rear brake circuit/renewing brake fluid............. 31 Additionally with [ABS].................................. 32 Checking clutch operating fluid level............................ 32 (Inspections I, II and III).................................. 32 Checking tightness of rear wheel studs........................... 33 (Inspection I)............................................... 33 Checking rear wheel bearing play by tilting wheel................ 33 (Inspection III)............................................. 33 Checking swinging arm bearings, adjusting if neces............... 33 (Inspections I and III)...................................... 33 Greasing the side (prop) stand pivot............................. 33 (Inspections I, II and III).................................. 33 Checking function of side (prop) stand contact swi............... 33 (Inspections I, II, III and IV).............................. 33 Tightening cylinder heads........................................ 34 (Inspection I)............................................... 34 Checking/adjusting valve operating clearances.................... 34 (Inspections I, II and III).................................. 34 Checking/renewing spark plugs.................................... 35 (Inspection II)/renewing (Inspection III).................... 35 Check synchronising.............................................. 35 (Inspections I, II and III).................................. 35 Final inspection with road safety and functional c............... 36 (Inspections I, II, III and IV).............................. 36 Road safety check............................................ 36 Roadworthiness check......................................... 36 11 Motor............................................................. 37 Sectioned drawing of engine...................................... 47 Lubricating oil circuit.......................................... 48 Coolant circuit.................................................. 49 Removing engine.................................................. 51 Dismantling engine............................................... 54 Removing cylinder head cover................................. 55 Locking the engine in the TDC position....................... 56 Top dead centre on ignition stroke:...................... 56 Removing and installing chain tensioner...................... 57 Assembly specification for timing chain tensioner:....... 57 Removing valve gear holder................................... 58 Dismantling/reassembling valve gear holder................... 59 Removing cylinder head....................................... 61 Dismantling, checking, repairing and re-assembling........... 62 Removing and installing valves........................... 62 Removing valve stem seals................................ 62 Checking valves for wear................................. 63 Remachining valve seat................................... 63 Checking and repairing cylinder head..................... 63 Checking valve guide for wear............................ 63 Replacing valve guides................................... 64 Installing valve and valve stem seal..................... 65 Removing cylinder barrel..................................... 66 Removing/dismantling piston.................................. 66 Checking pistons and cylinders............................... 67 Assembling pistons........................................... 67 Removing/installing conrod................................... 68 Removing and installing alternator cover with engi........... 69 Removing alternator mount cover.............................. 69 Renewing radial shaft seal in alternator mount cov........... 70 Renewing radial shaft seal for rotary breather............... 70 Removing auxiliary shaft drive............................... 71 Removing oil pump............................................ 72 Removing radial shaft seal on crankshaft with engi........... 73 Dismantling crankcase........................................ 74 Removing crankshaft, auxiliary shaft and timing ch........... 76 Removing and installing oil pick-up basket................... 77 Replacing oil level sight glass.............................. 77 Removing conrods............................................. 77 Checking conrods............................................. 77 Measuring main and big end bearing play...................... 78 Measuring radial bearing play............................ 78 Installing main bearing.................................. 79 Measuring axial bearing play............................. 79 Measuring big end bearing play............................... 80 Assembling engine................................................ 81 Installing conrod............................................ 81 Installing crankshaft........................................ 82 Installing timing chain tensioning and slide rails........... 82 Installing auxiliary shaft/timing chains..................... 82 Assembling engine block...................................... 83 Installing the crankshaft radial seal........................ 85 Installing clutch housing.................................... 86 Installing oil pump.......................................... 87 Installing auxiliary shaft drive............................. 88 Installing piston............................................ 89 Installing cylinder.......................................... 90 Installing cylinder head..................................... 91 Adjusting valve clearances................................... 92 Installing right cylinder head............................... 93 Adjustment specification................................. 93 Installing left cylinder head................................ 94 Adjustment specification................................. 94 Installing alternator mount cover............................ 96 Installing magnetic gate/belt pulley......................... 96 Timing the ignition...................................... 97 Installing alternator........................................ 98 Installing engine................................................ 99 12 Engine electrics..................................................101 Removing and installing coil and ignition lead...................105 Check ignition coil resistance...............................105 Removing and installing alternator...............................106 Poly-V belt adjusting procedure:.............................106 Dismantling/reassembling alternator..............................107 Checking alternator..........................................107 Checking armature for short to ground (earth)................107 Removing and installing starter motor............................108 Dismantling/reassembling starter motor...........................109 Renewing carbon brushes......................................109 Checking starter motor.......................................109 Checking starter relay.......................................109 Removing and installing magnetic gate............................110 Timing the ignition..........................................111 13 Fuel preparation and control......................................113 Removing and installing air cleaner..............................117 Removing and installing throttle stub pipe.......................117 Removing and installing throttle potentiometer...................117 Removing and installing throttle positioner......................118 Removing and installing throttle potentiometer...................118 Removing and installing injectors................................118 Removing and installing Motronic control unit....................119 16 Fuel tank and lines...............................................121 Removing and installing fuel tank................................125 Removing and installing fuel filter, fuel pump and...............126 Removing and installing fuel filter..........................126 Removing and installing fuel pump and fuel level s...........127 Checking fuel pump pressure..............................127 Removing and installing fuel distributor and press...............127 18 Exhaust system....................................................129 Removing and installing exhaust system...........................131 Removing and installing silencer (muffler)...................131 Removing and installing front exhaust pipes..................131 21 Clutch............................................................133 Removing and installing clutch hydraulic line....................138 Removing and installing clutch slave cylinder....................138 Filling/bleeding clutch line.....................................139 Removing and installing clutch...................................137 Removing clutch..............................................137 Installing clutch............................................137 23 Gearbox...........................................................141 Removing and installing gear pedal...............................145 Removing gearbox.................................................145 Renewing the shaft sealing rings in the gearbox ho...........147 Renew the input shaft sealing ring at the input en.......147 Renewing output shaft sealing ring.......................147 Renewing input shaft sealing ring at output side.........148 Renewing shaft sealing ring for selector drum............148 Renewing sealing ring for selector shaft.................148 Dismantling gearbox..............................................149 Removing gearbox housing.....................................149 Removing selector drum.......................................150 Dismantling/assembling selector shaft........................150 Removing gearbox shafts......................................151 Renewing deep-groove ball bearing on intermediate ...........151 Dismantling/assembling input shaft...........................152 Dismantling input shaft..................................152 Assembling input shaft...................................153 Dismantling/reassembling output shaft........................154 Stripping down output shaft..............................154 Assembling output shaft..................................155 Checking endplay.............................................156 Checking/adjusting fully compressed length of gear...........157 Checking/adjusting fully-compressed length of inte.......157 Checking/adjusting fully-compressed length of outp.......158 Checking/adjusting fully-compressed length of inpu.......159 Checking/adjusting fully-compressed length of sele.......160 Shimming selector shaft......................................161 Assembling gearbox...............................................162 Installing input, output and intermediate shaft..............162 Installing selector shaft....................................163 Installing selector drum.....................................163 Assembling gearbox housing...................................164 31 Front fork........................................................167 Removing and installing telescopic fork..........................171 Removing and installing telescopic fork......................171 Removing and installing fork bridge......................171 Removing and installing pot-type joints..................172 Removing and installing ball thrust bearing..............173 Removing and installing slider tube bridge...................174 Removing and installing ball joint.......................174 Checking friction at ball joint/ball thrust bearin...........174 Assembly specification for telescopic fork:..............175 Dismantling/reassembling telescopic fork.........................176 Dismantling telescopic fork..................................176 Assembling telescopic fork...................................176 Measuring telescopic fork........................................177 Check slider tube bridge.....................................177 Checking runout of fixed tube................................177 Removing and installing leading link.............................178 Dismantling/reassembling leading link............................178 Removing and installing front suspension strut...................178 32 Steering..........................................................179 Removing and installing left handlebar fitting...................183 Removing and installing right handlebar fitting..................184 Removing and installing handlebar................................185 Removing/installing throttle cable...............................186 33 Rear wheel drive..................................................187 Removing, dismantling, reassembling and installing...............191 Removing rear wheel drive....................................191 Removing input bevel pinion..................................191 Disassembling input bevel pinion.............................193 Removing needle roller bearing for input bevel pin.......193 Installing needle roller bearing for input bevel p.......193 Assembling input bevel pinion................................194 Installing input bevel pinion................................195 Removing and dismantling the crown wheel.....................196 Assembling/installing crown wheel............................197 Checking/adjusting backlash..................................198 Checking tooth contact pattern...............................199 Shimming housing cover.......................................200 Installing housing cover.....................................200 Installing splined element...................................200 Removing/installing rear swinging fork...........................201 Removing rear swinging arm...................................201 Removing and installing taper roller bearing.................202 Removing and installing flexible gaiter......................202 Removing drive shaft.........................................202 Checking universal joint for wear........................202 Installing drive shaft.......................................202 Installing rear swinging arm.................................203 Installing rear wheel drive..................................204 Removing and installing suspension strut.........................205 34 Brakes............................................................207 Removing and installing front brake caliper......................211 Dismantling and assembling front brake caliper...................212 Dismantling front brake caliper..............................212 Assembling front brake caliper...............................212 Removing and installing rear brake caliper.......................213 Dismantling and assembling rear brake caliper....................214 Dismantling rear brake caliper...............................214 Assembling rear brake caliper................................214 Removing and installing front brake disc.........................215 Removing/installing rear brake disc..............................216 Removing and installing front ABS sensor.........................217 Adjusting front ABS sensor gap...................................218 Marking sensor wheel.........................................218 Checking and adjusting sensor gap............................218 Removing and installing rear ABS sensor..........................219 Adjusting rear ABS sensor gap....................................220 Marking sensor wheel.........................................220 Checking and adjusting sensor gap............................220 Removing and installing rear brake master cylinder...............221 Checking and adjusting relief clearance of piston ...........221 Removing and installing brake pedal..............................221 Removing and installing ABS unit.................................222 Removing the ABS unit........................................222 Installing the ABS unit......................................223 Removing and installing ABS relay and relay base.................224 Removing ABS relay...........................................224 Installing the ABS relay.....................................224 Removing ABS relay base......................................224 Installing the ABS relay base................................225 Removing and installing brake lines..............................226 Removing and installing front brake line.....................226 Removing and installing rear brake line......................227 36 Wheels and tyres..................................................229 Removing and installing front wheel..............................233 Removing front wheel.........................................233 Installing front wheel.......................................233 Removing and installing wheel bearings.......................234 Removing/installing rear wheel...................................236 Static balancing of front wheel/rear wheel.......................237 Checking front/rear wheel rim for runout.........................238 Removing/installing spokes.......................................239 Centering the wheel rim..........................................239 Centering lateral runout.....................................239 46 Frame.............................................................241 Removing and installing rear mudguard............................245 Removing/installing front mudguard...............................245 Removing and installing front frame..............................246 Removing and installing rear frame...............................248 Removing/installing footrest supports............................250 Removing and installing side (prop) stand........................250 Checking running gear............................................251 Measuring wheel track offset.................................251 51 Equipment.........................................................253 Removing and installing ignition switch/steering l...............255 Removing and installing ignition/light switch................255 Removing and installing lock barrel..........................255 Drilling out lock barrel.................................255 Removing and installing lock barrel for fuel tank ...............256 Drilling out lock barrel.....................................256 52 Seat..............................................................257 Removing and installing seat.....................................259 61 General electrical equipment......................................261 Removing and installing central electrical equipme...............265 Relay positions (central electrical equipment box)...............266 Connections to fuses:........................................266 Frame wiring harness.............................................267 Wiring harness View from left................................268 Wiring harness View from right...............................272 62 Instruments.......................................................277 Removing and installing instrument cluster.......................281 Dismantling and assembling instrument cluster....................281 63 Lights............................................................283 Removing and installing headlight................................287 Adjusting headlight..........................................287
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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