BMW R 1200 CL Reparaturanleitung

Stöbern Sie online oder laden Sie Reparaturanleitung nach Motorräder BMW R 1200 CL herunter. BMW R 1200 CL Repair manual Benutzerhandbuch

  • Herunterladen
  • Zu meinen Handbüchern hinzufügen
  • Drucken
  • Seite
    / 150
  • Inhaltsverzeichnis
  • LESEZEICHEN
  • Bewertet. / 5. Basierend auf Kundenbewertungen

Inhaltsverzeichnis

Seite 1 - Repair Manual

R 850 CR 1200 CRepair Manual

Seite 2 - Introduction

00.411 EngineOil filterOil filter 11Oil drain plug 32Oil pumpMesh filter basket to engine block 9Oil pump cover 9Pressure relief valve 35Oil pressure

Seite 4 - Pre-delivery check

12.312Technical data R 850 C R 1200 CStarter motorType Permanent-magnet motor with planetary gear driveGear ratios Planetary gears 5.5 : 1Power rating

Seite 6

12.5Removing and installing coil and ignition lead•Remove fuel tank.e Caution:Switch off ignition. Disconnect ground (earth) cable at battery and insu

Seite 7

12.6Removing and installing alternator•Remove seat.•Remove fuel tank.e Caution:Switch off ignition. Disconnect ground (earth) cable at battery and ins

Seite 8

12.7Dismantling/reassembling alternator•Take out the cover retaining screws (1).•Release clips (2) and remove the cover.•Remove voltage regulator (3).

Seite 9 - Tightening torques

12.8Removing and installing starter motore Caution:Disconnect earth (ground) lead from battery.Insulate earth (ground) lead.•Release starter motor cov

Seite 10

12.9Dismantling/reassembling starter motor•Detach lead (1).•Remove retaining screws (2).•Remove flange (3).•Remove solenoid switch (4) after taking ou

Seite 11

12.10Removing and installing magnetic gate•Remove seat.•Unscrew fuel tank mount.•Pull fuel tank to the rear and support it at the front with a piece o

Seite 12

12.11Timing the ignition•Screw dial gauge holder, BMW No. 00 2 650,and dial gauge, BMW No. 00 2 510, into right or left spark plug hole.•Turn the engi

Seite 13

00.512 Engine electricsStarter motor to engine 20Starter cover to housing 7Positive lead to starter motor 10Alternator to cover mount 20Tensioning and

Seite 15 - Table of operating fluids

13.1Contents Page13Technical data ...

Seite 17 - Key to maintenance intervals

13.313Technical data R 850 C R 1200 CFuel grade Super (premium), unleaded, 95 octane (RON)Mixture preparation Motronic MA 2.4Throttle stub pipe intl.

Seite 19

13.5Removing and installing air cleanera See Group 46 (Removing/installing rear frame)Removing and installing throttle stub pipe•Remove throttle stub

Seite 20 - 13 3 010

13.6Removing and installing throttle positioner•Remove the throttle positioner (3).e Caution:The throttle positioner operates at the control unit volt

Seite 21

13.7Removing and installing Motronic control unit•Remove fuel tank.e Caution:Switch off ignition; disconnect earth (ground) lead at battery and insula

Seite 23

16.1Contents Page16Technical data ...

Seite 24 - Checking brake fluid level

00.623 TransmissionOil filler plug 23Oil drain plug 55Gearbox to engine block 22Gear shift pedal to rear frame 41Selector lever to selector shaft 9Gea

Seite 26

16.316Technical data R 850 C R 1200 CFuel tankTank capacity l (Imp. gal/US gal) 17 (3.74/4.50)including reserve of l (Imp. gal/US gal) 4 (0.88/1.06)Fu

Seite 28

16.5Removing 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:

Seite 29

16.6Removing and installing fuel filter, fuel pump and fuel level sensore Caution:Fuel is flammable and a hazard to health. Observe relevant safety re

Seite 30

16.7Removing and installing fuel pump and fuel level sensor•Detach the electrical connections at the fuel pump (4).•Release the hose clip at the fuel

Seite 32

18.1Contents Page18Removing and installing exhaust system ...3Removing and instal

Seite 34

18.318Removing and installing exhaust systemRemoving and installing silencer(muffler)•Unscrew fuel tank and pull to the rear.•Separate the plug connec

Seite 35 - 11 Motor

00.734 BrakesBrake caliper at fork slider tube 40Brake caliper to rear wheel drive 40Brake disc to front wheel 24 (clean thread + Loctite 2701)34 Brak

Seite 37

21.1Contents Page21Technical data ...

Seite 39

21.321Technical data R 850 C R 1200 CType of clutch single dry plate with increased-leverage dia-phragm springOperation hydraulic, with master and sla

Seite 41

21.5Removing and installing clutchRemoving clutcha Preparatory work is as for “Removinggearbox” (see Group 23)•Lock the clutch housing with special to

Seite 42

21.6Removing and installing clutch hydraulic line•Remove fuel tank.•Remove the battery.•[ABS] Drain the brake system.e Caution:Do not allow brake flui

Seite 43

21.7Filling/bleeding clutch linee Caution:Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid dest

Seite 45 - Sectioned drawing of engine

23.1Contents Page23Technical data ...

Seite 46 - Lubricating oil circuit

00.846 FrameFrame to engineM12 pin 82M10 screw 58Rear frame to engine 41to gearbox 71Side (prop) stand pivot mount to engine 21Side (prop) stand to pi

Seite 48

23.323Technical data R 850 C R 1200 CType of gearbox 5-speed gearbox with claw-action shift and inte-gral reaction damper for all gearsGear shift type

Seite 50

23.5Removing and installing gear pedalX Tightening torque:Gear pedal to frame ... 41 NmRemoving gearboxe Caution:Swi

Seite 51

23.6•Separate the side (prop) stand swithc plug.•Separate the neutral indicator plug.•Detach the left plug holder plate.•Remove the injectors.•Pull th

Seite 52 - 11 4 650

23.7Renewing the shaft sealing rings in the gearbox housing and gearbox coverL Note:All shaft sealing rings can be renewed with the gear-box installed

Seite 53 - 12 3 510

23.8Renewing input shaft sealing ring at output side•Pierce the shaft sealing ring with piercing tool, BMWNo.008583.•Screw the pull rod, BMW No. 00 8

Seite 54 - 11 2 650

23.9Dismantling gearboxRemoving gearbox housing•Take out oil filler/level check screw (2).•Take out oil drain plug (7) and drain the oil out of the ge

Seite 55

23.10Removing 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 (

Seite 56 - Removing valve gear holder

23.11Removing gearbox shafts•Remove breather tube (3).•Heat bearing points in gearbox cover to80 °C … 100 °C (176 °F ... 212 °F).•Take off input shaft

Seite 57 - RS110080

00.9Table of operating fluidsItem Use Order number QuantityLubricantOptimoly MP 3 High-performance lubricating paste 07 55 9 062 476 100 g tubeOptimol

Seite 58

23.12Dismantling/assembling input shaftDismantling input shaft•Clamp the input shaft into the vise, using soft jaws.•Use universal puller, BMW No. 00

Seite 60 - 11 1 250

00.11Key to maintenance intervals– BMW Inspection 1000 km/600 miles I– BMW Service II– BMW Inspection III– BMW Annual Service IVReading out MoDiTeC fa

Seite 61 - RS110890

00.12Changing engine oil, renew oil filter element(Inspections I, II, III and IV)L Note:If the motorcycle is ridden only for short distances or outsid

Seite 62

00.13Changing oil in gearbox(Inspections III and IV)or at least every 2 years•Change the gearbox oil while at regular operating temperature.•Loosen cl

Seite 63 - 11 5 602

IntroductionThis repair manual will help you to perform all the main maintenance and repair work correctly and efficient-ly. It should be consulted re

Seite 64 - Removing/dismantling piston

00.14Renewing 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 00

Seite 65 - RS110190

00.15•Drain fuel tank.•Remove fuel pump assembly.•Detach hoses from fuel filter (1).e Caution:Note correct direction of flow through fuel filter.Use o

Seite 66

00.16Checking battery acid level/topping up if necessary, cleaning/greasing battery posts(Inspections III and IV)•Release the rubber strap holding the

Seite 67 - RS110230

00.17Renewing 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 pu

Seite 68 - RS110241

00.18Checking brake system for correct operation and freedom from leaks; repairing/renewing if necessary(Inspection III)•Checking brake system for lea

Seite 69 - RS110961

00.19Checking brake pads and discs for wear/renewing(Inspections II and III)Checking front brake pad wear•Examine the wear limit marks (arrows).e Caut

Seite 70 - Removing oil pump

00.20Renewing brake padsFront brake•Detach/remove brake caliper from mounting (ar-row).•Remove the split-pin keeper (1) from the retain-ing pin (2).•D

Seite 71

00.21Renewing brake fluid and bleeding brake systemRenew the brake fluid annually(Inspection IV)[ABS Inspection II and III]Bleeding front brake circui

Seite 72 - Dismantling crankcase

00.22Additionally with [ABS]•Connect the brake bleeding device to the pres-sure modulator for the front brake (arrow); this is marked VR.•Open the ble

Seite 73 - Remove screws on left side

00.23Bleeding rear brake circuit/renewing brake fluidL Note:On motorcycles with ABS, start at the pressure modulator.•Use the auxiliary stand, BMW No.

Seite 74 - RS110290

Order No. 01 71 0 008 872 UX-VS-2, 06.99 Printed in GermanyCustomer Licence plate No.Order No. Mechanic’s signatureBMW Inspection at 1000 km (600 mile

Seite 75

00.24Additionally with [ABS]•Connect the brake bleeding device to the bleed screw on the pressure modulator for the rear brake (arrow); this is marked

Seite 76 - RS110310

00.25Checking tightness of rear wheel studs(Inspection I)•Tighten the rear wheel studs with a torque wrench.X Tightening torque:Rear wheel studs ...

Seite 77 - 00 2 510

00.26Tightening cylinder heads (Inspection I)•Remove cylinder head cover.e Caution:Trap escaping oil.•Select a gear and turn the rear wheel, or set th

Seite 78

00.27Checking/renewing spark plugs(Inspection II)/renewing (Inspection III)•Unscrew and remove spark plugs with the spark plug wrench, BMW No. 12 3 51

Seite 79

00.28Final inspection with road safety and functional check(Inspections I, II, III and IV)Road safety check•Check wheels and tyres.•Check/correct tyre

Seite 80

11.1Contents Page11Technical data ...

Seite 81 - Assembling engine block

11.2Contents PageRemoving alternator mount cover ...33Renewing r

Seite 82 - RS110391

11.3Installing right cylinder head ...57Adjustment sp

Seite 84

11.511Technical data R 850 C R 1200 CEngine, generalEngine design Four-stroke flat twin, air-cooled with oil-cooled exhaust ports, installed longitudi

Seite 85

Order No. 01 71 0 008 872 UX-VS-2, 06.99 Printed in GermanyCustomer Licence plate No.Order No. Mechanic’s signatureBMWPre-delivery checkCheck the ship

Seite 86 - RS110250

11.6Technical data R 850 C R 1200 CValvesIncluded angle between valves ° 41Valve clearances with engine cold (max. 35 °C/95 °F)0.15 (0.006)0.30 (0.012

Seite 87 - by 120° in each

11.7Technical data R 850 C R 1200 CValve guideValve guide Extl. dia. mm (in) 12.533...12.544 (0.4934...0.4939)Bore in cylinder head mm (in) 12.500...1

Seite 88 - 11 2 900

11.8Technical data R 850 C R 1200 CBucket-type tappetExtl. dia. mm (in) 23.947...23.960 (0.9428...0.9433)Bore dia. in cylinder head mm (in) 24.000...2

Seite 89

11.9Technical data R 850 C R 1200 CConnecting rodBore dia. for big end bearing mm (in) 51.000...51.013 (2.0079...2.0084)Big end bearing dia. mm (in) 4

Seite 90

11.10Technical data R 850 C R 1200 CPiston rings1st groove Piston ringasymmetrical, convex ovalHeight mm (in) 1.170...1.190 (0.0461...0.0469)Wear limi

Seite 91 - RS110150

11.11Sectioned drawing of engine

Seite 92 - Installing left cylinder head

11.12Lubricating oil circuit

Seite 93

11.13Coolant circuit

Seite 95

11.15Removing engineL Note:Auxiliary shaft, timing chains, chain tensioner/guide rails and crankshaft can only be dismantled after the engine has been

Seite 96

00 Maintenance and general instructions11 Motor12 Engine electrics13 Fuel preparation and control16 Fuel tank and lines18 Exhaust system21 Clutch23 Ge

Seite 97

11.16•Remove rear swinging fork.•Press off drive shaft.•Remove the air intake stub pipe.•Remove brake fluid reservoir from holder.•Remove the holder.•

Seite 98

11.17•Detach the central earth (ground) wire at the en-gine block.•Remove the left air intake pipe at the cylinder head.•Heat the ball joint mount at

Seite 99 - 12 Engine electrics

11.18Dismantling engine•Attach engine mount, BMW No. 11 0 630, to the engine block.•Transfer engine to assembly frame.•Drain engine oil.•Remove the oi

Seite 100

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

Seite 101

11.20Locking the engine in the TDC position•Remove front cover.•Turn the belt pulley to move the piston to TDC on the ignition stroke.Top dead centre

Seite 102

11.21Removing and installing chaintensionere Caution:Do not accidentally confuse the chain tensioner pis-tons. When installing, fit a new gasket.Assem

Seite 103 - 12 3 520

11.22Removing valve gear holder•Remove camshaft sprocket cover.•Unscrew/press off camshaft sprocket.L Note:If the camshaft sprocket (1) is not removed

Seite 104 - X Tightening torque:

11.23Dismantling/reassembling valve gear holder•Remove bearing cap.•Insert a suitable drift into the bore (arrow) of the rocker shaft, and pull the sh

Seite 105

11.24•Remove camshaft bearing cap (1).•Remove camshaft and bearings (2).•Remove bucket-type tappets.e Caution:Do not accidentally confuse the bucket-t

Seite 106

11.25Removing cylinder headRS110110M6 x 30M6 x 30M6 x 30M10 x 70

Seite 107 - RS120080

34 Brakes36 Wheels and tyres46 Frame51 Equipment52 Seat61 General electrical equipment62 Instruments63 LightsGroup / Chapter

Seite 108

11.26Dismantling, checking, repairing and re-assembling cylinder headRemoving and installing valvese Caution:Do not scratch sealing face on cylinder h

Seite 109 - 00 2 650

11.27Checking valves for wear•Clean combustion residue from valves.•Check valve dimensions.a ...See Technical

Seite 110

11.28Replacing valve guides•Heat cylinder head slowly and uniformly to 200 °C (392 °F) in a suitable oven.e Caution:Wear protective gloves when handli

Seite 111 - Contents Page

11.29Installing valve and valve stem sealL Note:If a valve was removed, the valve stem seal must be renewed.•Oil the stem when installing the valve.•S

Seite 112

11.30Removing cylinder barrel•Unscrew and remove guide rail bearing screw (1).•Unscrew and remove cylinder retaining screws, and remove cylinder.e Cau

Seite 113

11.31Checking pistons and cylindersReference temperature for measurements: ... 20 °C (68 °F)•Measure cylinder bore with internal probe at 20 mm (0.

Seite 114

11.32Removing/installing conrod•Turn crankshaft to TDC position.•Lock the clutch housing with special tool BMW No. 11 5 640.•Remove conrod.L Note:Conr

Seite 115

11.33Removing and installing alternator cover with engine installede Caution:Disconnect earth (ground) lead from battery. Insulate earth (ground) lead

Seite 116

11.34Renewing radial shaft seal in alternator mount cover•Carefully lever radial shaft seal out, using a screwdriver.•Drive in the new radial shaft se

Seite 117

11.35Removing auxiliary shaft drive•Align markings (arrows) on timing pinion and chain sprocket.•Unscrew and remove cooling oil pipe (1)/swing the pip

Seite 118

00.1Contents Page00Tightening torques ...

Seite 119 - 16 Fuel tank and lines

11.36Removing oil pump•Remove oil pump cover (1).•Remove complete oil pump (2) together with cooling oil pipe (3), and dismantle.e Caution:Check insta

Seite 120

11.37Removing radial shaft seal on crankshaft with engine installed•Lock clutch housing with special tool BMW No. 11 5 640.•Remove the clutch. •Carefu

Seite 121

11.38Dismantling crankcase•Turn engine on to its side.•Remove screws on right side.RS110261M10 x 100‹M10 x 100‹M8 x 80M8 x 80M8 x 35M8 x 35

Seite 122

11.39•Turn engine on to its side.•Remove screws on left side.•Remove upper section of crankcase.RS110260M6 x 50M6 x 50M6 x 50M6 x 50M6 x 25M6 x 25M10

Seite 123

11.40Removing crankshaft, auxiliary shaft and timing chain tensioning and slide railsRS110290

Seite 124

11.41Removing and installing oil pick-up basketX Tightening torque:M 6 screw ... 9 Nme Caution:Make

Seite 125

11.42Measuring main and big end bearing playMeasuring radial bearing play•Measure main bearing journal with an external micrometer crosswise in two pl

Seite 126

11.43Installing main bearing•Insert tensioner rail/slide rail pivot pin (1) for centering purposes.•Tighten M8 and M10 housing screws.X Tightening tor

Seite 127 - 18 Exhaust system

11.44Measuring big end bearing play•Measure crankpin with an external micrometer in the thrust direction and offset through 90o.•Install bearing shell

Seite 128

11.45Assembling engineInstalling conrod•Clamp crankshaft in a vise provided with protec-tive jaws.•Oil the big end bolts, screw them in by hand and ti

Seite 129

00.2Contents PageRear brakeChecking brake pads and discs for wear/renewing ...19(Inspections II and

Seite 130

11.46Installing crankshafte Caution:Oil the bearings.Installing timing chain tensioning and slide rails•Seal pivot pin for tensioning rail/slide rail

Seite 131 - 21 Clutch

11.47Assembling engine block•Coat clean, grease-free sealing faces (arrow) with 3-Bond 1209.•Secure the timing chain with rubber band (1) to the timin

Seite 132

11.48•Bolt the crankcase sections together.X Tightening torque/tightening order:1. M10 screw (oiled) ... 45 Nm2. M 8

Seite 133

11.49Installing 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/

Seite 134

11.50Installing clutch housinge Caution:Always use new bolts for housing and cover.•Install clutch housing with mark (1) aligned with crankshaft mark

Seite 135

11.51Installing oil pumpe Caution:Oil the sliding-contact faces.•Install outer rotor (1) of oil pump in pump hous-ing.•Install oil pump housing with c

Seite 136

11.52Installing auxiliary shaft drive•Set crankshaft mark against mark on auxiliary shaft.e Caution:Adjust according to the adjusting instructions.a .

Seite 137 - Filling/bleeding clutch line

11.53Installing piston•Turn joint in oil scraper ring (arrow) so that it fac-es upwards.•Install piston ring gap offset by 120° in each case.Productio

Seite 138

11.54Installing cylinder•Apply 3-Bond 1209 to the cylinder base sealing face (arrow), which must be clean and free from grease.•Oil the cylinder wall.

Seite 139 - 23 Gearbox

11.55Installing cylinder head•Install cylinder head gasket.•Fit cylinder head/insert correctly positioned cam-shaft chain sprocket (1) and timing chai

Seite 140

00.300Tightening torques Model R 850/1200 CConnection Nm11 EngineCylinder headTightening sequence:1. Tighten cylinder head nuts (oiled) crosswise1.1

Seite 141

11.56Adjusting valve clearances•Set piston to TDC on the ignition stroke.•Measure valve clearance with feeler gauge.•Correct valve clearance with adju

Seite 142

11.57Installing right cylinder headAdjustment specificatione Caution:When assembling, always start with the right cylin-der.Right cylinder = at TDC on

Seite 143

11.58Installing left cylinder headAdjustment specificatione Caution:When installing, always begin with the right cylin-der.Left cylinder = TDC on igni

Seite 144 - 23 1 820

11.59•Install the end cover with an O-ring which is in good condition.X Tightening torque:M 6 screw ...

Seite 145

11.60Installing alternator mount cover•Place sliding sleeve, BMW No. 11 5 680, on crankshaft.•Apply 3-Bond 1209 to the sealing face (arrow), which mus

Seite 146

11.61Timing 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

Seite 147

11.62Installing alternator•Install alternator.Poly-V belt adjusting procedure:Poly-V belt installation procedure:•Screw hex nut (1) on adjusting screw

Seite 148 - KR230050

11.63•Install oil filter with oil filter wrench, BMW No. 11 4 650.•Insert and tighten oil drain plug with a new seal.X Tightening torque:Oil filter (s

Seite 150 - KR230090

12.1Contents Page12Technical data .............................

Kommentare zu diesen Handbüchern

Keine Kommentare