Bmw R1200C (1999) User Manual [ru]

Repair Manual

R 850 C R 1200 C

BMW AG Motorcycle Division

After Sales

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 efficiently. 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 manufacturer’s specification.

●The repair manual is structured in the logical sequence of the work to be performed: Removal, Dismantling, 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

BMW AG Motorcycle Division Maintenance schedule

R 1100 S / R 850/1200 C / R 1150 GS

	Customer	Licence plate No.
	Order No.	Mechanic’s signature

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*)

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 *)

Renew fuel filter *)

normally every 40 000 km (24 000 miles), if fuel quality is poor every 20 000 km (12 000 miles)

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

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 *)

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

Order No. 01 71 0 008 872 UX-VS-2, 06.99

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

										every
										2 years
						40 000				every
						(24 000)				2 years
						40 000
						(24 000)

60 000

(36 000)

								40 000				every
								(24 000)				2 years

Printed in Germany

BMW AG Motorcycle Division Pre-delivery check

R 1100 S / R 850/1200 C / R 1150 GS

Customer		Licence plate No.
Order No.		Mechanic’s signature

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

Pre-delivery check

Order No. 01 71 0 008 872

UX-VS-2, 06.99

Printed in Germany

Contents

Group / Chapter

00 Maintenance and general instructions

11Motor

12Engine electrics

13Fuel preparation and control

16Fuel tank and lines

18Exhaust system

21Clutch

23Gearbox

31Front fork

32Steering

33Rear wheel drive

Group / Chapter

34 Brakes

36 Wheels and tyres

46 Frame

51Equipment

52Seat

61 General electrical equipment

62Instruments

63Lights

00 Maintenance and general instructions

Contents	Page
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

00.1

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

00.2

00

Tightening torques

Model			R 850/1200 C
Connection			Nm
11 Engine
Cylinder head
Tightening sequence:
1. Tighten cylinder head nuts (oiled) crosswise
	1.1 Tighten all nuts to correct torque for joint		20
	1.2 Tighten all nuts to correct angle	90°
	1.3 Tighten all nuts to correct angle	90°
2. M 10 bolt			40
3. M 6 screw			9
After 1000 km (600 miles), tighten cylinder head nuts
crosswise:
1.	Unfasten one nut
2.	Tighten one nut to initial value		20
3.	Tighten nut to wrench angle	180°
4.	Unfasten/retighten M10 screw		40
Timing gear carrier to cylinder head			9
Bearing cap on rocker shaft			15
Locknut, valve adjusting screw			8
Cylinder head cover to cylinder head			9
Camshaft end cover to cylinder head			9
Air intake connection to cylinder head			9
Camshaft
Chain sprocket to camshaft			65
Camshaft bearing cap			15
Rotary breather
Vent line to alternator mount cover
M 8 screw			20
Banjo screw			25
Alternator mount cover
M 6 screw			9
M 8 screw			20
Auxiliary shaft
Chain sprocket to crankshaft			10
Chainwheel to auxiliary shaft			70
Chain tensioner housing to engine block			9

00.3

		Model				R 850/1200 C
		Connection				Nm
		11 Engine
		Oil filter
		Oil filter				11
		Oil drain plug				32
		Oil pump
		Mesh filter basket to engine block				9
		Oil pump cover				9
		Pressure relief valve				35
		Oil pressure switch				30
		Oil cooler
		Oil cooler pipe to engine block				10
		Cooling oil line - banjo screw with oil vent valve				25
		Oil cooler to frame				9
		Oil cooler return line to engine block				35
		Screw-in union for oil cooler connection at engine				35 (clean threads and apply Loctite 603 to inner
		block				and outer threads and in the contact face area)
		Cylinders
		Tightening sequence:
		1. M 8 screw				20
		2. M 6 screw				9
		3.	Chain guide rail pivot screw			18
		Timing chain
		Chain tensioner				32
		Connecting rod
		Big end cap		Joint torque		20
				Additional wrench
				angle	80°
		Crankcase
		Tightening sequence:
		1.	M10 screw (oiled)			45
		2.	M 8 screw (oiled)			20
		3. M 6 screw				9

00.4

Model			R 850/1200 C
Connection			Nm
12 Engine electrics
Starter motor to engine			20
Starter cover to housing			7
Positive lead to starter motor			10
Alternator to cover mount			20
Tensioning and retaining strap at alternator			20
Spacer at alternator			20
Positive lead to alternator			15
Belt pulley at alternator			50
Belt pulley to crankshaft			50
Poly-V belt preload			8
Spark plug			20
Ignition coil holder to frame			9
13 Fuel preparation and control
Oil temperature sensor to engine block			25
Air temperature sensor to air cleaner cover			10
16 Fuel tank and lines
Fuel tank to rear frame			10
18 Exhaust system
Manifold to cylinder head			24
Clip on muffler			55	(apply Never Seez to clip contact surface)
Oxygen sensor (lambda probe) to muffler			45	(apply Never Seez to thread)
21 Clutch
Clutch housing	Joint torque		40	(oil screw threads lightly)
	Additional wrench
	angle	32°
Housing cover			12
Slave cylinder to gearbox			9
Clutch line to handlebar fitting			18

00.5

		Model		R 850/1200 C
		Connection		Nm
		23 Transmission
		Oil filler plug		23
		Oil drain plug		55
		Gearbox to engine block		22
		Gear shift pedal to rear frame		41
		Selector lever to selector shaft		9
		Gearbox cover to gearbox housing		9
		31 Front fork
		Fixed tube to fork bridge		35	(free from oil and grease)
		Slider tube bridge to slider tube		22	(clean thread + Loctite 243)
		Quick-release axle clamp screws		20
		Threaded journal to frame		130 (clean thread + Loctite 243)
		Ball joint to fork slider bridge		230 (apply light coat of Never Seez to thread)
		Leading link to ball joint		130 (clean thread + Loctite 2701)
		Leading link to engine	right	73
		Screw cap at leading link	left	42	(apply light coat of Never Seez to thread)
		Spring strut to frame		40
		Spring strut to leading link		40
		32 Steering
		Handlebar at fork bridge		21	(apply light coat of Never Seez to thread)
		Twistgrip to handlebar		8
		33 Rear wheel drive
		Oil filler plug		23
		Oil drain plug		23
		Threaded ring		118 (Hylomar SQ 32 M)
		Hexagon nut, input bevel gear		200 (clean thread + Loctite 2701)
		Cover at rear-wheel drive housing		35
		Rear-wheel drive to swinging arm		24
		Swinging arm bearing journal to rear frame	right	9
		Swinging arm bearing journal to rear frame	left	7 (clean thread + Loctite 2701)
		Locknut at swinging arm bearing journal		160
		Suspension strut to rear frame		50
		Suspension strut to rear swinging arm		50

00.6

Model		R 850/1200 C
Connection		Nm
34 Brakes
Brake caliper at fork slider tube		40
Brake caliper to rear wheel drive		40
Brake disc to front wheel		24 (clean thread + Loctite 2701)
34 Brakes
Brake disc to rear wheel drive		21 (clean thread + Loctite 2701)
Master cylinder to footrest assembly		8
Brake pedal to footrest assembly		37
Brake lines/brake hose to brake
components		18
ABS sensor		4 (handtight)
Front brake caliper bleed screw		7
Rear brake caliper bleed screw		4
Pressure modulator bleed screw		9
36 Wheels and tyres
Quick-release axle clamp screws		20
Quick-release axle threaded connection		30
Rear wheel to rear wheel drive
Screw wheel studs in handtight, then tighten
in a crosswise pattern
Initial tightening		50
Final tightening		105

00.7

		Model		R 850/1200 C
		Connection		Nm
		46 Frame
		Frame to engine
		M12 pin		82
		M10 screw		58
		Rear frame
		to engine		41
		to gearbox		71
		Side (prop) stand pivot mount to engine		21
		Side (prop) stand to pivot mount		42 (clean thread + Loctite 243)
		Footrest assembly to engine
		M12 screw		71
		M8 screw		21
		Pillion footrest holder to rear frame		21
		Pillion seat mount		21
		Mudguard to slider tube bridge		8
		51 Equipment
		Mirrors		15
		Ignition/steering lock to fork bridge		15 (shear bolt)
		61 General electrical equipment
		Horn to holder		13
		Ground (earth) strap to engine block		10
		63 Lights
		Headlight to holder		15

00.8

Table of operating fluids

Item	Use	Order number	Quantity
Lubricant
Optimoly MP 3	High-performance lubricating paste	07 55 9 062 476	100 g tube
Optimoly TA	High-temperature assembly paste	18 21 9 062 599	100 g tube
Silicone grease 300, heavy	Damping grease	07 58 9 058 193	10 g tube
Retinax EP2	Wheel, steering head and taper roller	83 22 9 407 845	100 g tube
	bearing grease
Contact spray	Contact spray	81 22 9 400 208	300 ml aerosol
Chain spray	Drive chain	72 60 2 316 676	50 ml spray
		72 60 2 316 667	300 ml spray
Sealants
3-Bond 1110 B	Surface sealant	07 58 9 056 998	5 g tube
3-Bond 1209	Surface sealant	07 58 9 062 376	30 g tube
omni VISC 1002	Surface sealant	07 58 1 465 170	90 g tube
Loctite 574	Surface sealant	81 22 9 407 301	50 ml tube
Curil K 2	Heat-conductive sealant	81 22 9 400 243	250 g can
Hylomar SQ 32 M	Permanently elastic sealant	81 22 9 400 339	100 g tube
Adhesives and retaining
agents
Loctite 648	Joint adhesive (low clearance)	07 58 9 067 732	5 g bottle
Loctite 638	Joint adhesive (greater clearance)	07 58 9 056 030	10 ml bottle
Loctite 243	Thread retainer, medium-strength	07 58 9 056 031	10 ml bottle
Loctite 270	Thread retainer, strong	81 22 9 400 086	10 ml bottle
Loctite 2701	Thread retainer, strong	33 17 2 331 095	10 ml bottle
Loctite 454	Cyanacrylate adhesive (gel)	07 58 9 062 157	20 g tube
Cleaner
Brake cleaner	Brake cleaner	83 11 9 407 848	600 ml aerosol
Metal Polish	Polish for chromium plated parts	82 14 9 400 890	100 g tube
Testing agent
Penetrant MR 68	Crack testing agent for aluminum	83 19 9 407 855	500 ml spray
	housings
Entwickler MR 70	Crack testing agent for aluminum	81 22 9 407 495	500 ml spray
	housings

00.9

00.10

Key to maintenance intervals

–BMW Inspection

	1000 km/600 miles	I
–	BMW Service	II
–	BMW Inspection	III
–	BMW Annual Service	IV

Reading out MoDiTeC fault memory

(Inspections I, II, III and IV)

•Remove the left air cleaner trim panel.

•Connect MoDiTeC to diagnostic plug.

•Read out the fault memory.

•Perform any repair work indicated.

Checking throttle cable play, adjusting if necessary

(Inspections I and III)

•Check throttle cable for free movement and freedom from abrasion or kinking; renew if necessary.

•With the steering turned to various angles, open the throttle twistgrip fully and allow it to close again.

•When released, the twistgrip must return to the closed position by itself.

C000010

•Pull back the protective cap.

•Preset throttle cable play with the engine cold to 1.5 mm (0.06 in).

•Warm the engine up to its regular operating temperature.

•Adjust throttle cable play to 0.5 mm (0.02 in).

Adjusting value:
Initial throttle cable play setting
(engine cold) .................................	1.5 mm (0.06 in)
Throttle cable play (engine warm) ..	0.5 mm (0.02 in)

00.11

Changing engine oil, renew oil filter element

(Inspections I, II, III and IV)

L Note:

If the motorcycle is ridden only for short distances or outside temperatures are below 0°C (32°F): change the oil and renew the oil filter element every

3 months, but at least every 3 000 km (1 800 miles).

•Change the oil while it is at regular operating temperature.

C000240

• Remove screw plug.

•Unscrew oil drain plug and drain off oil.

•Fit new seal and screw in drain plug.

11 4 650

C000030

•Use oil filter wrench, BMW No. 11 4 650, to unscrew and remove the oil filter.

•Coat sealing ring on new oil filter element with oil and screw in.

•Add oil.

•Insert and tighten the screw plug.

•Check engine oil level with the motorcycle in a horizontal position; use the auxiliary stand,

BMW No. 00 1 550.

eCaution:

Never add engine oil above the MAX mark.

X Tightening torque:

Oil filter.........................................................	11 Nm
Oil drain plug................................................	32 Nm
Fill quantity for engine:
With oil
filter change ..	3.75 l (6.6 Imp. pints/3.96 US quarts)
Without oil
filter change ..	3.50 l (6.2 Imp. pints/3.69 US quarts)
Oil volume between MIN and
MAX marks......	0.50 l (0.88 Imp. pint/0.52 US quart)

Engine oil grade:

Brand-name HD oil for four-stroke spark-ignition engine, API classifications SE, SF, SG; combination with CC or CD specification.

00.12

Changing oil in gearbox

(Inspections III and IV) or at least every 2 years

•Change the gearbox oil while at regular operating temperature.

2		3

1

C000040

•Loosen clip/trim (1) at right silencer and turn downwards.

•Take out oil filler plug (3) and oil drain plug (2) and allow the oil to drain out.

•Clean the magnet in the oil drain plug.

•Insert the oil drain plug again.

Changing oil in rear wheel drive; cleaning inductive signal transmitter at rear wheel

(Inspections I, III and IV)

Every 40 000 km (24 000 miles) or at least every 2 years

•Change the gearbox oil while at regular operating temperature.

5

6

4

C000050

e Caution:

Note that the interior of the gearbox is slightly pressurised.

L Note:

Add oil to the gearbox up to the lower edge of the filler hole, then place the motorcycle on its side (prop) stand and add the remaining 0.2 litre

(0.35 Imp. pint, 0.21 US quart).

•Add gearbox oil.

•Insert oil filler plug with new seal.

X Tightening torque:
Oil drain plug	................................................	55 Nm
Oil filler plug .................................................		23 Nm
Exhaust pipe ...........clip at silencer (muffler)		55 Nm
Fill quantity:
Initial filling.......	1.0 l (1.76 Imp. pints/1.06 US quart)
During
oil changes......	1.0 l (1.76 Imp. pints/1.06 US quart)

Oil grade for gearbox:

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

•Slacken off oil drain plug (4) so that the pressure drops.

•Unscrew and remove oil filler plug (5).

•Unscrew and remove oil drain plug (4) and allow the oil to drain out.

•Fit new seal and screw in drain plug.

•Add gearbox oil.

•Insert oil filler plug with new seal.

•Release the fastening, pull out inductive signal transmitter (6) and clean it.

X Tightening torque:
Oil drain plug................................................		23 Nm
Oil filler plug .................................................		23 Nm
Fill quantity:
Initial filling up to lower edge of filler
hole.........	app. 0.20 l (0.35 Imp. pint/0.21 US quart)
Oil change up to lower edge of filler
hole.........	app. 0.20 l (0.35 Imp. pint/0.21 US quart)

Oil grade for rear wheel drive:

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

00.13

13 3 010

C160010

Renewing fuel filter

(Inspection III)

In normal operating conditions every 40 000 km (24 000 miles); if fuel quality is poor every

20 000 km (12 000 miles)

•Remove seat.

•Remove right air cleaner trim panel.

•Remove left and right trim panels.

e Caution:

Fuel is flammable and a hazard to health. Observe relevant safety regulations.

•Take off the fuel tank.

•Seal the fuel feed and return lines with a hose clip, BMW No. 13 3 010, detach and pull off.

•Pull the plug connector off the fuel pump assembly.

•Lift off fuel tank.

00.14

2

1

C160020

• Drain fuel tank.			X Tightening torque:
• Remove fuel pump assembly.
• Detach hoses from fuel filter (1).			Fuel pump unit ..............................................		5 Nm
e	Caution:		Installing:
Note correct direction of flow through fuel filter.
			L Note:
Use only an O-ring seal (2) in good condition.
After installing, check fuel pump assembly for leaks.			Note correct path of vent lines.

•Fit new fuel filter.

•Secure non-reusable hose clips with pliers,

BMW No. 13 1 500.

00.15

C000020

Checking battery acid level/topping	Renewing intake air cleaner
up if necessary, cleaning/greasing	element
battery posts

(Inspections III and IV)

•Release the rubber strap holding the battery.

•Raise the battery and check its acid level.

•Top up battery acid level with distilled water as far as the MAX mark.

Protective
battery-post grease: ...............	e.g. Bosch Ft 40 V1

(Inspection III)

In very dirty and dusty operating conditions, renew every 10 000 km (6 000 miles) or even more frequently if necessary

•Detach and raise the upper part of the air cleaner housing.

•Renew air cleaner element.

•Install the fuel tank.

•Note correct path of vent lines.

•Install the left/right trim panels.

X Tightening torque:
Fuel tank to rear frame .................................	10 Nm

00.16

Renewing Poly-V belt

(every 60 000 km/36 000 miles)

(Inspection III)

12 3 510

C000060

•Remove the cover.

•Use the spark plug cap assembly tool from the toolkit to pull off the spark plug caps.

•Use spark plug wrench, BMW No. 12 3 510, to unscrew and remove the spark plugs.

TDC

1

C000070

•Remove the horn with its mount.

•Remove front cover.

•Remove vent line (1).

3

2

4

1

RS110480

•Slacken off alternator mounting screws (1,3,4) and install a new Poly-V belt if necessary.

Poly-V belt adjusting procedure:

Poly-V belt installation procedure:

•Place the Poly-V belt in position, tension it and turn the engine over once, then release belt tension.

Poly-V belt tensioning procedure:

1.Screw hex nut (1) on adjusting screw (2) up handtight (no tools to be used)

2.Tighten adjusting screw (2) with a torque wrench and keep it under tension.

3.Tighten upper retaining nut (3), then release the tension at the adjusting screw.

4.Tighten all screws and nuts.

X Tightening torque:
Poly-V belt preload.........................................	8	Nm
Alternator to alternator support cover...........	20	Nm
Vent line at generator mount cover:
Banjo screw .................................................	25	Nm
Machine screw.............................................	10	Nm

e Caution:

Install the vent line with new O-ring seals.

00.17

Checking brake system for correct operation and freedom from leaks; repairing/renewing if necessary

(Inspection III)

• Checking brake system for leaks.

Checking brake fluid level

L Note:

The brake fluid volume (between MIN and MAX) is sufficient for the complete range of pad wear from new to the wear limit.

It is not normally necessary to add fluid to compensate for pad wear.

If the level drops below the minimum mark, this indicates some other fault.

(Inspections I, II and III)

Front brake

•Make sure that the specified setting (distance between handlebar and fuel tank 30-50 mm/ 1.2-2 in) is correct.

•Check with the motorcycle on its side (prop) stand.

•Turn the handlebar fully to the left.

•The brake fluid must not drop below the minimum level 2 mm (0.08 in) below the ring mark (arrow).

CUB0110

Brake fluid grade

.........................................DOT 4

Rear brake

•Position the motorcycle horizontally with auxiliary stand, BMW No. 00 1 550.

•Brake fluid must not drop below the minimum level (arrow).

C000090

Brake fluid grade .........................................

DOT 4

00.18

Checking brake pads and discs for wear/renewing

(Inspections II and III)

Checking front brake pad wear

C000100

Checking rear brake pad wear

C000120

It should not be possible to see the brake disc through the hole (arrow) in the inner brake pad.

If the brake disc is visible, the wear limit has been reached and the pads must be renewed.

C000110

• Examine the wear limit marks (arrows).

eCaution:

Brake pad thickness must not fall below the minimum value.

Change pads only as a complete set.

Minimum lining thickness: ..........

1.5 mm (0.06 in)

Checking brake disc wear

C000130

•Examine the brake discs carefully for cracks, damage, distortion, wear and score-marks.

Brake disc wear limit:
front:...........................................	4.5 mm (0.177 in)
rear:............................................	4.6 mm (0.181 in)

00.19

	Renewing brake pads	Renewing brake pads
	Front brake	Rear brake

C000100

C000140

•Detach/remove brake caliper from mounting (arrow).

1

2

C000230

•Remove the split-pin keeper (1) from the retaining pin (2).

•Drive out retaining pin (2).

•Remove brake pads by pulling downwards.

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

•Before installing the brake caliper, force the pistons fully back with resetting tool,

BMW No. 34 1 500.

X Tightening torque:
Brake caliper at fork slider tube....................	40 Nm

•Loosen the rear wheel.

•Unfasten/remove brake caliper.

•Remove circlip (arrow) at retaining pin.

•Drive the retaining pin out towards the wheel side.

•Remove brake pads.

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

•Before installing the brake caliper, depress the piston fully.

X Tightening torque:
Brake caliper to rear wheel drive ..................	40	Nm
Screw the rear wheel studs in handtight, then
tighten them in a crosswise pattern.
Initial tightening ............................................	50	Nm
Final tightening...........................................	105	Nm

00.20

Renewing brake fluid and bleeding brake system

Renew the brake fluid annually (Inspection IV)

[ABS Inspection II and III]

Bleeding front brake circuit/renewing brake fluid

L Note:

This description applies to brake filling and bleeding devices with vacuum extraction of the brake fluid at the brake caliper.

If other devices are used, comply with their manufacturers’ instructions.

• Turn the steering to the left.

eCaution:

When bleeding the brakes, always start on the right side.

•Take off the brake caliper.

•Remove the brake pads.

34 1 500

C000150

•Force the pistons fully back with resetting tool,

BMW No. 34 1 500.

eCaution:

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

•Take off reservoir cover with rubber diaphragm.

•Release the right handlebar switch.

•Loosen the clamp screw for the handbrake fitting and turn the fitting until the brake fluid reservoir is horizontal.

KR340280

e Caution:

When adding brake fluid, do not allow it to enter the holes for the reservoir lid screws.

•Add brake fluid up to the MAX mark (arrow).

•Connect the brake bleeding device to the bleed screw on the right brake caliper.

•Open the bleed screw by half a turn.

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

•Close the bleed screw on the right brake caliper.

•Repeat the bleeding process at the left brake caliper.

When installing:

L Note:

Clean the rim of the reservoir, the rubber gaiter and the cover to remove brake fluid, and re-assemble the components with great care.

e Next check brake fluid level with the motorcycle on its side (prop) stand and the handlebar turned to the left, and ensure that no air bubbles are visible in the sight glass.

00.21

Additionally with [ABS]

							34 1 520
			C000160						C000170

•Connect the brake bleeding device to the pressure modulator for the front brake (arrow); this is marked VR.

•Open the bleed screw by half a turn.

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

•Close the bleed screw.

•Bleed the left brake caliper in precisely the same way as on the right.

•If necessary, repeat the brake bleeding procedure at the right/left.

X Tightening torque:
Bleed screw on pressure modulator...............	9 Nm

•Take out the resetting tool and insert spacer,

BMW No. 34 1 520, in its place.

•Press the pistons back in the second brake caliper, but do not remove the resetting tool.

•Fill and bleed the front brake circuit.

•Installation takes place in the reverse order of removal.

Brake fluid grade .........................................	DOT 4
X Tightening torque:
Brake caliper to fork tube .............................	40	Nm
Bleed screw at brake caliper ..........................	7	Nm

00.22