2002-2003 BMW R1200C OEM Service & Repair Manual
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BMW AG Motorcycle Division
After Sales
R 850 C
R 1200 C
Repair Manual
Published by: © BMW AG Motorcycle Division
After Sales
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
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 towards achieving even higher Service
quality.
A new issue of this repair manual will be published if amendments or additions (supplements) are needed.
The latest issue date is shown in the header of the microfiche. Microfiches rendered invalid by the new issue
should be destroyed without delay.
All information in both text and illustrations refers to motorcycles in standard condition or with Original BMW
accessories installed, and not to motorcycles which have been modified in any way to depart from the man-
ufacturer’s specification.
● The repair manual is structured in the logical sequence of the work to be performed: Removal, 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 without interruption.
● 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 you to consult the
detailed illustrations on the Parts microfiches as an additional source of information.
BMW AG Motorcycle Division
After Sales
Published by: BMW AG Sparte Motorrad
Hufelandstr. 6
D - 80937 München
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.
Produced in Germany
Order No. 01 71 0 008 872 UX-VS-2, 06.99 Printed in Germany
Customer Licence plate No.
Order No. Mechanic’s signature
BMW Inspection
at 1000 km
(600 miles)
BMW Service
every 10 000 km
(6 000 miles)
BMW Inspection
every 20 000 km
(12 000 miles)
BMW
Annual Service
Read the fault code memory with the MoDiTeC
Change oil while at regular operating temperature and renew the oil filter element
if motorcycle is used only for short journeys or at outside temperatures under 0°C (32 °F), every
3 months, but at least every 3 000 km (1 800 miles) *
)
Change oil in gearbox while at operating temperature
at least every 2 years*
)
every
2 years
Change oil in rear wheel drive while at regular operating temperature;
if necessary, clean inductive sensor on rear wheel
every 40 000 km (24 000 miles) or at least every 2 years *
)
40 000
(24 000)
every
2 years
Renew fuel filter *
)
normally every 40 000 km (24 000 miles), if fuel quality is poor every 20 000 km (12 000 miles)
40 000
(24 000)
Check battery acid level, if necessary add distilled water
Clean and grease the battery terminals, if necessary
Renew intake air filter element
in very dusty or dirty operating conditions, renew the intake air filter element every 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 fluid level
Change the clutch fluid
every 40 000 km (24 000 miles) or at least every 2 years *
)
40 000
(24 000)
every
2 years
Check tightness of rear wheel studs
Check rear wheel bearing play by tilting wheel
Check swinging arm bearings (zero play); adjust if necessary *
)
Grease the side stand pivot
Check function of side stand contact switch
Check condition of spark plugs
Renew spark plugs *
)
Check security of cylinder head nuts
Check/adjust valve clearances
Check throttle cable for free movement, abrasion and kinking; renew if necessary *
)
Check cable play
Check synchronisation and eliminate leaks *
)
Final inspection with road safety and functional check:
– Condition of tyres and wheels, rims and spokes if applicable, tyre pressures
– Lights and signalling equipment
– Telltale and warning lights
– Clutch, gear shift
– Front and rear brakes, steering
– Instruments
– If necessary, test ride
*
)
Charged as an additional item
BMW AG Motorcycle Division
Maintenance schedule
R 1100 S / R 850/1200 C / R 1150 GS
Order No. 01 71 0 008 872 UX-VS-2, 06.99 Printed in Germany
Customer Licence plate No.
Order No. Mechanic’s signature
BMW
Pre-delivery check
Check the shipping crate for damage
Motorcycle:
– unpack
– install remaining items
– inspect for damage
– check that delivery is complete: tools
documentation
keys
correct optional extras
Fill and charge the battery (mark with charging date)
Check engine oil level when cold; add oil if necessary
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 optional extras, ABS
– If necessary, test ride
Confirm pre-delivery check in Service and Technical Booklet
Final cleaning
Motorcycle handed over on:
BMW AG Motorcycle Division
Pre-delivery check
R 1100 S / R 850/1200 C / R 1150 GS
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
34 Brakes
36 Wheels and tyres
46 Frame
51 Equipment
52 Seat
61 General electrical equipment
62 Instruments
63 Lights
Group / Chapter
00.1
Contents Page
00
Tightening torques ......................................................................................................................3
Table of operating fluids ...........................................................................................................9
Key to maintenance intervals .............................................................................................. 11
Reading out MoDiTeC fault memory ............................................................................... 11
(Inspections I, II, III and IV)
Checking throttle cable play,
adjusting if necessary .............................................................................................................. 11
(Inspections I and III)
Changing engine oil, renew oil filter element ............................................................. 12
(Inspections I, II, III and IV)
Changing oil in gearbox .......................................................................................................... 13
(Inspections III and IV)
or at least every 2 years
Changing oil in rear wheel drive; cleaning inductive signal transmitter at
rear wheel ....................................................................................................................................... 13
(Inspections 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 dirty and dusty operating conditions, renew every 10 000 km (6 000 miles) or even more fre-
quently if necessary
Renewing Poly-V belt ............................................................................................................... 17
(every 60 000 km/36 000 miles)
(Inspection III)
Poly-V belt adjusting procedure:
Checking brake fluid level ......................................................................................................... 18
Front brake
00 Maintenance and general instructions
00.2
Contents Page
Rear brake
Checking brake pads and discs for wear/renewing ...................................................... 19
(Inspections II and III)
Checking front brake pad wear .............................................................................................. 19
Checking rear brake pad wear ................................................................................................ 19
Checking brake disc wear ........................................................................................................ 19
Renewing brake pads Front brake ........................................................................................ 20
Renewing brake padsRear brake .......................................................................................... 20
Renewing brake fluid and bleeding brake system ................................................... 21
Renew the brake fluid annually
(Inspection IV)
[ABS Inspection II and III]
Bleeding front brake circuit/renewing brake fluid ........................................................... 21
Additionally with [ABS]
Bleeding rear brake circuit/renewing brake fluid ............................................................ 23
Additionally with [ABS]
Checking clutch operating 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)
Tightening cylinder heads ..................................................................................................... 26
(Inspection I)
Checking/adjusting valve operating clearances ...................................................... 26
(Inspections I, II and III)
Checking/renewing spark plugs ........................................................................................ 27
(Inspection II)/renewing (Inspection III)
Check synchronising ................................................................................................................ 27
(Inspections I, II and III)
Final inspection with road safety and functional check ....................................... 28
(Inspections I, II, III and IV)
Road safety check
Roadworthiness check
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Get the complete service and repair manual for the 2002-2003 BMW R1200C motorcycle. This comprehensive guide includes all the necessary troubleshooting and replacement procedures recommended by the manufacturer. It features step-by-step instructions, detailed images, and exploded-view illustrations, making it an essential resource for both professional mechanics and DIY enthusiasts.
Regular maintenance is crucial for ensuring the longevity of your motorcycle. Over time, certain parts will wear out and require replacement. With this manual, you'll have access to the manufacturer's recommended troubleshooting charts and procedures, enabling you to address issues and maintain your bike's reliability. By utilizing this manual, you can save on repair costs and minimize the need for professional assistance.
It's important to note that this is not a generic repair manual but the official OEM manual utilized by professional technicians. You won't have to sift through numerous pages to locate specific information, as the manual provides clear instructions and illustrations. Additionally, it's easily accessible and searchable, offering a more convenient alternative to traditional bound manuals. You can even print out a physical copy if preferred.
- Printable: Yes
- Language: English
- Compatibility: Compatible with various electronic devices, including PC, Mac, Android, and Apple devices
- Requirements: Adobe Reader (free)
