BMW AG Motorcycle (R 850 C, R 1200 C). Manual - part 15

21.1

Contents

Page

................................................................................................................................3

Removing and installing clutch

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

Removing clutch

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

Installing clutch

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

Removing and installing clutch hydraulic line

.............................................................6

Removing and installing clutch slave cylinder

.............................................................6

Filling/bleeding clutch line

......................................................................................................7

21 Clutch

21.3

Technical data

R 850 C

R 1200 C

Type of clutch

single dry plate with increased-leverage dia-
phragm spring

Operation

hydraulic, with master and slave cylinders

Master cylinder piston Ø

mm (in) 13 (0.51)

Slave cylinder piston Ø

mm (in) 24 (0.94)

Clutch fluid

DOT 4 brake fluid

Clutch plate dia.

mm (in) 165 (6.50)

Wear dimension

mm (in) 4.6 (0.18)

(measured on rivets of clutch plate using tips of
sliding caliper, pressed together by hand)

21.5

Removing and installing clutch

Removing clutch

Preparatory work is as for “Removing
gearbox” (see Group 23)

•

Lock the clutch housing with special tool
BMW No. 11 5 640.

•

Remove the clutch.

Installing clutch

•

Install clutch housing with mark (1) aligned with
crankshaft mark (2).

•

Lock the clutch housing with special tool
BMW No. 11 5 640.

Caution:

Always use new bolts for housing and cover.

•

Insert all screws by hand and tighten down.

Tightening torque:

Clutch housing to crankshaft
(oil screw threads lightly)
Initial tightening ............................................ 40 Nm
Wrench angle .................................................... 32°

•

Install clutch.

Caution:

Offset the color marks on the clutch housing, driven
plate and housing cover through 120° in each case.

•

Secure the clutch with the retaining screws.

•

Center the clutch plate with centering pin,
BMW No. 21 2 673.

•

Tighten retaining screws alternately in a cross-
wise pattern.

Lubrication points:
Splines on clutch plate and gearbox input shaft.
Diaphragm spring contact surface on clutch hous-
ing.
Diaphragm spring contact surface on pressure
plate.

............................................... Optimoly MP3 paste

Tightening torque:

Housing cover to flywheel ............................ 12 Nm

11 5 640

C210010

21.6

Removing and installing clutch
hydraulic line

•

Remove fuel tank.

•

Remove the battery.

•

[ABS] Drain the brake system.

Caution:

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

•

[ABS] Remove the ABS unit.

•

Remove battery carrier.

•

Drain the clutch operating system.

Caution:

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

•

Detach the clutch line at the separating point (1).

•

Detach the clutch slave cylinder and pull it to the
rear with the line.

•

Detach the lines at the clutch slave cylinder.

•

Install by following the above work instructions in
the reverse order.

•

Fill the clutch operating system.

•

[ABS] Add fluid to brake system.

Note:

When installing, fit new sealing rings.

Tightening torque:

Clutch line to handlebar fitting ...................... 18 Nm

Removing and installing clutch
slave cylinder

•

Remove fuel tank.

Caution:

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

•

Detach clutch line at separating point (1).

•

Detach and raise the central electrical equipment
box at the left.

•

Detach the clutch slave cylinder and pull it to the
rear with the line.

•

Detach lines at clutch slave cylinder.

•

Remove clutch slave cylinder.

•

Install by following the above work instructions in
the reverse order.

•

Fill the clutch operating system.

Note:

When instaling, fit new sealing rings.

Tightening torque:

Clutch slave cylinder to gearbox .................... 9 Nm

C210030

21.7

Filling/bleeding clutch line

Caution:

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

Note:

The description applies to a brake system filling and
bleeding device with vacuum extraction of brake flu-
id at the bleed line.
If other devices are used, comply with their manu-
facturers’ instructions.

•

Take off reservoir cover with rubber diaphragm.

•

[Standard handlebar/Police] Raise motorcycle
on auxiliary stand, BMW No. 00 1 560, and
swing handlebar fully to right.

•

[Optional handlebar/Easy Rider] Prop motorcy-
cle on side stand and turn handlebar fully to right.

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.

Note:

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

•

Top up the brake fluid.

•

Bleed the clutch line through bleed screw (2).

Caution:

During the bleeding operation the brake fluid must
not drop below the MIN mark or else air will be
drawn into the clutch operating system. If this oc-
curs, repeat the bleeding operation.

•

Continue to draw off/pump through the brake flu-
id until it is clear and free from bubbles.

•

Close the bleed screw.

•

Correct the fluid level.

•

Replace the reservoir lid with rubber diaphragm
in position.

•

Tighten the reservoir cover without using force.

Operating materials
Brake fluid.....................................................DOT 4

CUB0100

23.1

Contents

Page

Technical data

................................................................................................................................3

Removing and installing gear pedal

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

Removing gearbox

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

Renewing the shaft sealing rings in the gearbox housing and gearbox cover

....7

Renew the input shaft sealing ring at the input end  .............................................................................7
Renewing output shaft sealing ring ......................................................................................................7
Renewing input shaft sealing ring at output side  .................................................................................8
Renewing shaft sealing ring for selector drum  .....................................................................................8
Renewing sealing ring for selector shaft  ..............................................................................................8

Dismantling gearbox

...................................................................................................................9

Removing gearbox housing

.......................................................................................................9

Removing selector drum

............................................................................................................10

Dismantling/assembling selector shaft

...............................................................................10

Removing gearbox shafts

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

Renewing deep-groove ball bearing on intermediate shaft

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

Dismantling/assembling input shaft

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

Dismantling input shaft ......................................................................................................................12
Assembling input shaft ......................................................................................................................13

Dismantling/reassembling output shaft

...............................................................................14

Stripping down output shaft ..............................................................................................................14
Assembling output shaft ....................................................................................................................15

Checking endplay

.........................................................................................................................16

Checking/adjusting fully compressed length of gearbox shafts, selector drum

Checking/adjusting fully-compressed length of intermediate shaft  ....................................................17
Checking/adjusting fully-compressed length of output shaft  .............................................................18
Checking/adjusting fully-compressed length of input shaft ................................................................19
Checking/adjusting fully-compressed length of selector drum  ..........................................................20

Shimming selector shaft

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

Assembling gearbox

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

Installing input, output and intermediate shaft

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

Installing selector shaft

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

Installing selector drum

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

Assembling gearbox housing

..................................................................................................24

23 Gearbox

23.3

Technical data

R 850 C

R 1200 C

Type of gearbox

5-speed gearbox with claw-action shift and inte-
gral reaction damper for all gears

Gear shift type

Pedal-operated lever and selector drum with
overshoot detent

Gear ratios

1st gear

3.864

2nd gear

3.022

3rd gear

2.393

4th gear

1.962

5th gear

1.511

Oil grade (all the year round)

Brand-name SAE 90 hypoid gear oil, API
Class GL 5

Filling capacity

Initial filling

l (Imp.

pint/

US quart

1.0
(1.76/1.06)
(up to the lower edge of the filler hole)

During oil changes

l (Imp.

pint/

US quart

approx. 0.8 +0.2
(1.41 +0.35/0.85 +0.21)
(up to the lower edge of the filler hole)

Endplay of spring segment at input shaft

mm (in) 0.4...0.6 (0.0157...0.0236)

Endplay at 1st gear, output shaft

mm (in) 0.1...0.33 (0.0039...0.0130)

Endplay at 2nd gear, output shaft

mm (in) 0.1...0.33 (0.0039...0.0130)

Endplay, 3rd/4th gear (total play),
output shaft

mm (in) 0.1...0.67 (0.0039...0.0264)

Selector shaft endplay

mm (in) 0.1...0.3 (0.0039...0.0118)

Length of intermediate shaft, fully
compressed

mm (in) 198.95...199.00 (7.833...7.835)

Length of output shaft, fully compressed

mm (in) 192.95...193.00 (7.597...7.599)

Length of input shaft, fully compressed

mm (in) 138.55...138.60 (5.455...5.457)

Length of selector drum, fully compressed

mm (in) 111.80...111.90 (4.402...4.406)

23.5

Removing and installing gear pedal

Tightening torque:

Gear pedal to frame ..................................... 41 Nm

Removing gearbox

Caution:

Switch off ignition.
Disconnect earth (ground) lead from battery.
Insulate earth (ground) lead.

•

Attach stand, BMW No. 00 1 520, to motorcycle.

•

Remove seat.

•

Remove side trim.

•

Remove fuel tank.

•

Remove rear wheel.

•

Detach rear brake caliper.

•

Detach ABS sensor.

•

Detach speedometer signal sensor.

•

Detach wire protection at swinging arm.

•

Tie up swinging arm with a suitable strap.

•

Remove suspension strut.

Note:

Press to rear at top.

•

Pull swinging arm upwards with strap.

•

Removing exhaust manifold.

•

Remove silencer (muffler).

•

Detach plug at oxygen sensor.

•

Remove rear wheel drive unit.

•

Detach brake hose holder.

•

Press off left swinging arm bearing cap.

Caution:

When installing again, make sure that the O-ring is
in good condition.
The opening must face down so that water can drain
out.

•

Loosen the left swinging arm.

•

Take out the screws at the right swinging arm
bearing.

•

Using pull rod, BMW No. 00 8 581, and impact
weight, BMW No. 00 8 582, pull out the swinging
arm bearing.

•

Remove the left swinging arm bearing.

•

Remove rear swinging fork.

•

Remove the rubber intake pipe sleeves.

•

Remove brake fluid reservoir from holder.

•

Remove the holder.

•

Detach the right plug holder plate.

•

Pull off the NTC air plug.

•

Detach the gear pedal at the pivot.

•

Separate the throttle potentiometer and throttle
angle positioner plugs at the left plug holder
plate.

•

Disconnect both fuse boxes at the plug holder
plate.

C230180

C330030

C330040

00 8 581

00 8 582

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