1997-2004 BMW R1200 R1200C Service & Repair Manual

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

1997-2004 BMW R1200 R1200C Service & Repair Manual

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