BMW AG Motorcycle (R 850 C, R 1200 C). Manual - part 4

 

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BMW AG Motorcycle (R 850 C, R 1200 C). Manual - part 4

 

 

00.24

Additionally with [ABS]

Connect the brake bleeding device to the bleed 
screw on the pressure modulator for the rear 
brake
 (arrow); this is marked HR.

Open the bleed screw by half a turn.

e

 Caution:

During brake bleeding, make sure that the fluid re-
plenishing hole is always below the level of the brake 
fluid, or else air will be drawn into the brake system. 
If this occurs, repeat the bleeding operation.

Draw off brake fluid until it emerges clear and 
free from air bubbles.

Close the bleed screw.

If necessary, repeat the bleeding procedure.

Brake fluid grade .........................................DOT 4

Tightening torque:

Bleed screw at pressure modulator................ 9 Nm

Checking clutch operating fluid 
level

(Inspections I, II and III)

e

 Caution:

Do not allow brake fluid to come into contact with 
painted parts of the motorcycle, because brake fluid 
destroys paint.

Place the motorcycle on the auxiliary stand, 
BMW No. 00 1 550.

Turn the steering to the right.

e

 Caution:

With the clutch lining in new condition the surface of 
the fluid (arrow) must be up to the lower edge of the 
ring mark; it must not be below normal.

L

 Note:

As the clutch lining wears, the fluid level in the res-
ervoir rises.

If necessary, take off reservoir cover with insert.

Correct the fluid level. Mark in reservoir: as for 
brake circuit.

Re-attach the reservoir cover with insert.

Tighten the reservoir cover without using force.

Brake fluid grade .........................................DOT 4

C000190

CUB0100

00.25

Checking tightness of rear wheel 
studs

(Inspection I)

Tighten the rear wheel studs with a torque 
wrench.

Tightening torque:

Rear wheel studs ....................................... 105 Nm

Checking rear wheel bearing play by 
tilting wheel

(Inspection III)

Tilt the rear wheel to and fro across its axle.

If play is detected, fit new shims to rear wheel 
drive or renew bearings.

Checking swinging arm bearings, 
adjusting if necessary

(Inspections I and III)

Grip rear tyre and try to move it sideways, brac-
ing against the frame.

Greasing the side (prop) stand pivot

(Inspections I, II and III)

Check free movement of side (prop) stand and 
grease if necessary.

Grease pivot point (arrow).

Lubricant:
For side (prop) stand pivot........... Shell Retinax EP2

Checking function of side (prop) 
stand contact switch

(Inspections I, II, III and IV)

Place the motorcycle on the auxiliary stand, 
BMW No. 00 1 550.

Select a gear and switch on the ignition.

Slowly extend the side (prop) stand and watch 
the neutral indicator light.

L

 Note:

As the stand is extended, the neutral indicator light 
should come on briefly.

C000200

00.26

Tightening cylinder heads 

(Inspection I)

Remove cylinder head cover.

e

 Caution:

Trap escaping oil.

Select a gear and turn the rear wheel, or set the 
piston to TDC on the ignition stroke by turning 
the belt pulley.

Top dead centre on ignition stroke:

The OT (TDC) mark is visible and the inlet and ex-
haust valves in the cylinder concerned are 
closed.

Tighten cylinder head nuts.

Tightening procedure after 1 000 km (600 miles)
1.

Tighten the cylinder head nuts one after the
other in a crosswise pattern

1.1. Slacken off one nut at a time
1.2. Tighten nut to initial torque.................... 20 Nm
1.3. Tighten nut to specified wrench angle ...... 180°
2.

Unfasten/retighten M10 screw .............. 40 Nm

Checking/adjusting valve operating 
clearances

(Inspections I, II and III)

Check valve clearance with feeler gauge and, if 
necessary, correct with adjusting nut/lock.

Adjust valve clearances with the engine cold 
(max. 35 °
C/95 °F):
Inlet ........................................... 0.15 mm (0.006 in)
Exhaust ..................................... 0.30 mm (0.012 in)

Tightening torque:

Locknut.......................................................... 8 Nm

After adjusting, check valve operating clearanc-
es again; it should be possible to pull the correct 
feeler gauge through between the valve stem 
and the adjusting screw with only slight resist-
ance.

Assemble in reverse order.

e

 Caution:

Make sure that gasket is correctly seated. Gaskets 
and sealing faces must be free from oil or grease.

Tightening torque:

Cylinder head cover ....................................... 8 Nm

C000210l

C000070

TDC

RS110980

00.27

Checking/renewing spark plugs

(Inspection II)/renewing (Inspection III)

Unscrew and remove spark plugs with the spark 
plug wrench, BMW No. 12 3 510.

e

 Caution:

Do not bend electrodes - risk of breakage!

Electrode gap:  .......................... 0.8 mm (0.031 in)
Gap wear limit:........................... 1.0 mm (0.039 in)

Tightening torque:

Spark plug.................................................... 20 Nm

Check synchronising

(Inspections I, II and III)

The engine must be at regular operating temper-
ature.

Connect the BMW Synchrotester hose to the 
vacuum stub pipe (arrow) and the lines to the 
MoDiTeC
.

L

 Note:

If the left/right readings differ by more than 30 milli-
bars (0.42 psi), check the air intake system for leaks.

C000060

12 3 510

C000220

00.28

Final inspection with road safety 
and functional check

(Inspections I, II, III and IV)

Road safety check

Check wheels and tyres.

Check/correct tyre pressures.

Wait at least 10 minutes after the trial run/road 
test before checking/correcting engine oil level.

Tyre pressures:
Solo ..................................... front 2.2 bar (31.3 psi)

............................................. rear 2.5 bar (35.6 psi)

With pillion passenger .......... front 2.5 bar (35.6 psi)

............................................. rear 2.7 bar (38.4 psi)

With pillion 
passenger + luggage............ front 2.5 bar (35.6 psi)

............................................. rear 2.9 bar (41.2 psi)

Roadworthiness check

Lights

Telltale/warning lights

Horn

Instruments

Special equipment

Clutch

Gear shift

Steering

Foot brake and handbrake

Trial run if necessary

11.1

Contents

Page

11

Technical data 

................................................................................................................................5

Sectioned drawing of engine 

...............................................................................................11

Lubricating oil circuit 

...............................................................................................................12

Coolant circuit 

..............................................................................................................................13

Removing engine 

........................................................................................................................15

Dismantling engine 

....................................................................................................................18

Removing cylinder head cover

 ................................................................................................19

Locking the engine in the TDC position

 ..............................................................................20

Top dead centre on ignition stroke: ...................................................................................................20

Removing and installing chain tensioner

 ............................................................................21

Assembly specification for timing chain tensioner:  ............................................................................21

Removing valve gear holder

 .....................................................................................................22

Dismantling/reassembling valve gear holder

 ....................................................................23

Removing cylinder head

 ............................................................................................................25

Dismantling, checking, repairing and re-assembling cylinder head

 ......................26

Removing and installing valves ..........................................................................................................26
Removing valve stem seals  ...............................................................................................................26
Checking valves for wear  ..................................................................................................................27
Remachining valve seat .....................................................................................................................27
Checking and repairing cylinder head  ...............................................................................................27
Checking valve guide for wear ...........................................................................................................27
Replacing valve guides ......................................................................................................................28
Installing valve and valve stem seal  ...................................................................................................29

Removing cylinder barrel

 ...........................................................................................................30

Removing/dismantling piston

 ..................................................................................................30

Checking pistons and cylinders

 .............................................................................................31

Assembling pistons

 ......................................................................................................................31

Removing/installing conrod

 ......................................................................................................32

Removing and installing alternator cover with engine installed

 ...............................33

11 Motor

11.2

Contents

Page

Removing alternator mount cover

 .........................................................................................33

Renewing radial shaft seal in alternator mount cover

 ...................................................34

Renewing radial shaft seal for rotary breather

 .................................................................34

Removing auxiliary shaft drive

 .................................................................................................35

Removing oil pump

 ......................................................................................................................36

Removing radial shaft seal on crankshaft with engine installed

 ...............................37

Dismantling crankcase

 ...............................................................................................................38

Removing crankshaft, auxiliary shaft and timing chain 
tensioning and slide rails

 ...........................................................................................................40

Removing and installing oil pick-up basket

 .......................................................................41

Replacing oil level sight glass

 .................................................................................................41

Removing conrods

 .......................................................................................................................41

Checking conrods

 ........................................................................................................................41

Measuring main and big end bearing play

 .........................................................................42

Measuring radial bearing play ............................................................................................................42
Installing main bearing .......................................................................................................................43
Measuring axial bearing play  .............................................................................................................43

Measuring big end bearing play

 .............................................................................................44

Assembling engine 

....................................................................................................................45

Installing conrod

 ............................................................................................................................45

Installing crankshaft

 .....................................................................................................................46

Installing timing chain tensioning and slide rails

 .............................................................46

Installing auxiliary shaft/timing chains

 ..................................................................................46

Assembling engine block

 ..........................................................................................................47

Installing the crankshaft radial seal

 .......................................................................................49

Installing clutch housing

 ............................................................................................................50

Installing oil pump

 .........................................................................................................................51

Installing auxiliary shaft drive

 ...................................................................................................52

Installing piston

 ..............................................................................................................................53

Installing cylinder

 ...........................................................................................................................54

Installing cylinder head

 ...............................................................................................................55

Adjusting valve clearances

 .......................................................................................................56

11.3

Installing right cylinder head

 ....................................................................................................57

Adjustment specification  ...................................................................................................................57

Installing left cylinder head

 .......................................................................................................58

Adjustment specification  ...................................................................................................................58

Installing alternator mount cover

 ............................................................................................60

Installing magnetic gate/belt pulley

 ......................................................................................60

Timing the ignition  .............................................................................................................................61

Installing alternator

 .......................................................................................................................62

Installing engine 

..........................................................................................................................63

 

 

 

 

 

 

 

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