R 850 CR 1200 CRepair Manual
00.411 EngineOil filterOil filter 11Oil drain plug 32Oil pumpMesh filter basket to engine block 9Oil pump cover 9Pressure relief valve 35Oil pressure
12.312Technical data R 850 C R 1200 CStarter motorType Permanent-magnet motor with planetary gear driveGear ratios Planetary gears 5.5 : 1Power rating
12.4
12.5Removing and installing coil and ignition lead•Remove fuel tank.e Caution:Switch off ignition. Disconnect ground (earth) cable at battery and insu
12.6Removing and installing alternator•Remove seat.•Remove fuel tank.e Caution:Switch off ignition. Disconnect ground (earth) cable at battery and ins
12.7Dismantling/reassembling alternator•Take out the cover retaining screws (1).•Release clips (2) and remove the cover.•Remove voltage regulator (3).
12.8Removing and installing starter motore Caution:Disconnect earth (ground) lead from battery.Insulate earth (ground) lead.•Release starter motor cov
12.9Dismantling/reassembling starter motor•Detach lead (1).•Remove retaining screws (2).•Remove flange (3).•Remove solenoid switch (4) after taking ou
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
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
00.512 Engine electricsStarter motor to engine 20Starter cover to housing 7Positive lead to starter motor 10Alternator to cover mount 20Tensioning and
12.12
13.1Contents Page13Technical data ...
13.2
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.
13.4
13.5Removing and installing air cleanera See Group 46 (Removing/installing rear frame)Removing and installing throttle stub pipe•Remove throttle stub
13.6Removing and installing throttle positioner•Remove the throttle positioner (3).e Caution:The throttle positioner operates at the control unit volt
13.7Removing and installing Motronic control unit•Remove fuel tank.e Caution:Switch off ignition; disconnect earth (ground) lead at battery and insula
13.8
16.1Contents Page16Technical data ...
00.623 TransmissionOil filler plug 23Oil drain plug 55Gearbox to engine block 22Gear shift pedal to rear frame 41Selector lever to selector shaft 9Gea
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
16.4
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:
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
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
16.8
18.1Contents Page18Removing and installing exhaust system ...3Removing and instal
18.2
18.318Removing and installing exhaust systemRemoving and installing silencer(muffler)•Unscrew fuel tank and pull to the rear.•Separate the plug connec
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
18.4
21.1Contents Page21Technical data ...
21.2
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
21.4
21.5Removing and installing clutchRemoving clutcha Preparatory work is as for “Removinggearbox” (see Group 23)•Lock the clutch housing with special to
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
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
21.8
23.1Contents Page23Technical data ...
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
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
23.4
23.5Removing and installing gear pedalX Tightening torque:Gear pedal to frame ... 41 NmRemoving gearboxe Caution:Swi
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
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
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
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
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 (
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
00.9Table of operating fluidsItem Use Order number QuantityLubricantOptimoly MP 3 High-performance lubricating paste 07 55 9 062 476 100 g tubeOptimol
23.12Dismantling/assembling input shaftDismantling input shaft•Clamp the input shaft into the vise, using soft jaws.•Use universal puller, BMW No. 00
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
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
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
IntroductionThis repair manual will help you to perform all the main maintenance and repair work correctly and efficient-ly. It should be consulted re
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
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
00.16Checking battery acid level/topping up if necessary, cleaning/greasing battery posts(Inspections III and IV)•Release the rubber strap holding the
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
00.18Checking brake system for correct operation and freedom from leaks; repairing/renewing if necessary(Inspection III)•Checking brake system for lea
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
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
00.21Renewing brake fluid and bleeding brake systemRenew the brake fluid annually(Inspection IV)[ABS Inspection II and III]Bleeding front brake circui
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
00.23Bleeding rear brake circuit/renewing brake fluidL Note:On motorcycles with ABS, start at the pressure modulator.•Use the auxiliary stand, BMW No.
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
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
00.25Checking tightness of rear wheel studs(Inspection I)•Tighten the rear wheel studs with a torque wrench.X Tightening torque:Rear wheel studs ...
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
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
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
11.1Contents Page11Technical data ...
11.2Contents PageRemoving alternator mount cover ...33Renewing r
11.3Installing right cylinder head ...57Adjustment sp
11.4
11.511Technical data R 850 C R 1200 CEngine, generalEngine design Four-stroke flat twin, air-cooled with oil-cooled exhaust ports, installed longitudi
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
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
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
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
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
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
11.11Sectioned drawing of engine
11.12Lubricating oil circuit
11.13Coolant circuit
11.14
11.15Removing engineL Note:Auxiliary shaft, timing chains, chain tensioner/guide rails and crankshaft can only be dismantled after the engine has been
00 Maintenance and general instructions11 Motor12 Engine electrics13 Fuel preparation and control16 Fuel tank and lines18 Exhaust system21 Clutch23 Ge
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.•
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
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
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
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
11.21Removing and installing chaintensionere Caution:Do not accidentally confuse the chain tensioner pis-tons. When installing, fit a new gasket.Assem
11.22Removing valve gear holder•Remove camshaft sprocket cover.•Unscrew/press off camshaft sprocket.L Note:If the camshaft sprocket (1) is not removed
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
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
11.25Removing cylinder headRS110110M6 x 30M6 x 30M6 x 30M10 x 70
34 Brakes36 Wheels and tyres46 Frame51 Equipment52 Seat61 General electrical equipment62 Instruments63 LightsGroup / Chapter
11.26Dismantling, checking, repairing and re-assembling cylinder headRemoving and installing valvese Caution:Do not scratch sealing face on cylinder h
11.27Checking valves for wear•Clean combustion residue from valves.•Check valve dimensions.a ...See Technical
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
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
11.30Removing cylinder barrel•Unscrew and remove guide rail bearing screw (1).•Unscrew and remove cylinder retaining screws, and remove cylinder.e Cau
11.31Checking pistons and cylindersReference temperature for measurements: ... 20 °C (68 °F)•Measure cylinder bore with internal probe at 20 mm (0.
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
11.33Removing and installing alternator cover with engine installede Caution:Disconnect earth (ground) lead from battery. Insulate earth (ground) lead
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
11.35Removing auxiliary shaft drive•Align markings (arrows) on timing pinion and chain sprocket.•Unscrew and remove cooling oil pipe (1)/swing the pip
00.1Contents Page00Tightening torques ...
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
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
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
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
11.40Removing crankshaft, auxiliary shaft and timing chain tensioning and slide railsRS110290
11.41Removing and installing oil pick-up basketX Tightening torque:M 6 screw ... 9 Nme Caution:Make
11.42Measuring main and big end bearing playMeasuring radial bearing play•Measure main bearing journal with an external micrometer crosswise in two pl
11.43Installing main bearing•Insert tensioner rail/slide rail pivot pin (1) for centering purposes.•Tighten M8 and M10 housing screws.X Tightening tor
11.44Measuring big end bearing play•Measure crankpin with an external micrometer in the thrust direction and offset through 90o.•Install bearing shell
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
00.2Contents PageRear brakeChecking brake pads and discs for wear/renewing ...19(Inspections II and
11.46Installing crankshafte Caution:Oil the bearings.Installing timing chain tensioning and slide rails•Seal pivot pin for tensioning rail/slide rail
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
11.48•Bolt the crankcase sections together.X Tightening torque/tightening order:1. M10 screw (oiled) ... 45 Nm2. M 8
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/
11.50Installing clutch housinge Caution:Always use new bolts for housing and cover.•Install clutch housing with mark (1) aligned with crankshaft mark
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
11.52Installing auxiliary shaft drive•Set crankshaft mark against mark on auxiliary shaft.e Caution:Adjust according to the adjusting instructions.a .
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
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.
11.55Installing cylinder head•Install cylinder head gasket.•Fit cylinder head/insert correctly positioned cam-shaft chain sprocket (1) and timing chai
00.300Tightening torques Model R 850/1200 CConnection Nm11 EngineCylinder headTightening sequence:1. Tighten cylinder head nuts (oiled) crosswise1.1
11.56Adjusting valve clearances•Set piston to TDC on the ignition stroke.•Measure valve clearance with feeler gauge.•Correct valve clearance with adju
11.57Installing right cylinder headAdjustment specificatione Caution:When assembling, always start with the right cylin-der.Right cylinder = at TDC on
11.58Installing left cylinder headAdjustment specificatione Caution:When installing, always begin with the right cylin-der.Left cylinder = TDC on igni
11.59•Install the end cover with an O-ring which is in good condition.X Tightening torque:M 6 screw ...
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
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
11.62Installing alternator•Install alternator.Poly-V belt adjusting procedure:Poly-V belt installation procedure:•Screw hex nut (1) on adjusting screw
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
11.64
12.1Contents Page12Technical data .............................
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