Bmw R1200 R1200c R 1200 C 1997 – 2004 Service Repair Manual
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Bmw R1200 R1200c R 1200 C 1997 – 2004 Service Repair Manual
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.
- 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.
TABLE OF CONTENTS:
Bmw R1200 R1200c R 1200 C 1997 – 2004 Service Repair Manual
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 frequently
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
002
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
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
112
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
113
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
Technical data 3
Removing and installing coil and ignition lead 5
Check ignition coil resistance 5
Removing and installing alternator 6
Poly-V belt adjusting procedure: 6
Dismantling/reassembling
alternator 7
Checking alternator 7
Checking armature for short to ground (earth) 7
Removing and installing starter motor 8
Dismantling/reassembling starter motor 9
Renewing carbon brushes 9
Checking starter motor 9
Checking starter relay 9
Removing and installing magnetic gate 10
Timing the ignition 11
Technical data 3
Removing and installing air cleaner 5
Removing and installing throttle stub pipe 5
Removing and installing throttle potentiometer 5
Removing and installing throttle positioner 6
Removing and installing throttle potentiometer 6
Removing and installing injectors 6
Removing and installing Motronic control unit 7
Technical data 3
Removing and installing fuel tank 5
Removing and installing fuel filter, fuel pump and fuel level sensor 6
Removing and installing fuel filter 6
Removing and installing fuel pump and fuel level sensor 7
Checking fuel pump pressure 7
Removing and installing fuel distributor and pressure regulator
Removing and installing exhaust system 3
Removing and installing silencer (muffler) 3
Removing and installing front exhaust pipes 3
Technical data 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
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 17
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
Technical data 3
Removing and installing telescopic fork 5
Removing and installing telescopic fork 5
Removing and installing fork bridge 5
Removing and installing pot-type joints 6
Removing and installing ball thrust bearing 7
Removing and installing slider tube bridge 8
Removing and installing ball joint 8
Checking friction at ball joint/ball thrust bearing 8
Assembly specification for telescopic fork: 9
Dismantling/reassembling telescopic fork 10
Dismantling telescopic fork 10
Assembling telescopic fork 10
Measuring telescopic fork 11
Check slider tube bridge 11
Checking runout of fixed tube 11
Removing and installing leading link 12
Dismantling/reassembling leading link 12
Removing and installing front suspension strut 12
Technical data 3
Removing and installing left handlebar fitting 5
Removing and installing right handlebar fitting 6
Removing and installing handlebar 7
Removing/installing throttle cable 8
Technical data 3
Removing, dismantling, reassembling and installing rear wheel drive 5
Removing rear wheel drive 5
Removing input bevel pinion 5
Disassembling input bevel pinion 7
Removing needle roller bearing for input bevel pinion 7
Installing needle roller bearing for input bevel pinion 7
Assembling input bevel pinion 8
Installing input bevel pinion 9
Removing and dismantling the crown wheel 10
Assembling/installing crown wheel 11
Checking/adjusting backlash 12
Checking tooth contact pattern 13
Shimming housing cover 14
Installing housing cover 14
Installing splined element 14
Removing/installing rear swinging fork 15
Removing rear swinging arm 15
Removing and installing taper roller bearing 16
Removing and installing flexible gaiter 16
Removing drive shaft 16
Checking universal joint for wear 16
Installing drive shaft 16
Installing rear swinging arm 17
Installing rear wheel drive 18
Removing and installing suspension strut 19
33 Rear wheel drive
332
Technical data 3
Removing and installing front brake caliper 5
Dismantling and assembling front brake caliper 6
Dismantling front brake caliper 6
Assembling front brake caliper 6
Removing and installing rear brake caliper 7
Dismantling and assembling rear brake caliper 8
Dismantling rear brake caliper 8
Assembling rear brake caliper 8
Removing and installing front brake disc 9
Removing/installing rear brake disc 10
Removing and installing front ABS sensor 11
Adjusting front ABS sensor gap 12
Marking sensor wheel 12
Checking and adjusting sensor gap 12
Removing and installing rear ABS sensor 13
Adjusting rear ABS sensor gap 14
Marking sensor wheel 14
Checking and adjusting sensor gap 14
Removing and installing rear brake master cylinder 15
Checking and adjusting reliefclearance of piston rod 15
Removing and installing brake pedal 15
Removing and installing ABS unit 16
34 Brakes
342
Contents Page
Removing the ABS unit 16
Installing the ABS unit 17
Removing and installing ABS relay and relay base 18
Removing ABS relay 18
Installing the ABS relay 18
Removing ABS relay base 18
Installing the ABS relay base 19
Removing and installing brake lines 20
Removing and installing front brake line 20
Removing and installing rear brake line 21
Technical data 3
Removing and installing front wheel 5
Removing front wheel 5
Installing front wheel 5
Removing and installing wheel bearings 6
Removing/installing rear wheel 8
Static balancing of front wheel/rear wheel 9
Checking front/rear wheel rim for runout 10
Removing/installing spokes 11
Centering the wheel rim 11
Centering lateral runout 11
Technical data 3
Removing and installing rear mudguard 5
Removing/installing front mudguard 5
Removing and installing front frame 6
Removing and installing rear frame 8
Removing/installing footrest supports 10
Removing and installing side (prop) stand 10
Checking running gear 11
Measuring wheel track offset 11
Removing and installing ignition switch/steering lock 3
Removing and installing ignition/light switch 3
Removing and installing lock barrel 3
Drilling out lock barrel 3
Removing and installing lock barrel for fuel tank filler cap 4
Drilling out lock barrel 4
Removing and installing seat 3
Technical data 3
Removing and installing central electrical equipment box 5
Relay positions (central electrical equipment box) 6
Connections to fuses: 6
Frame wiring harness 7
Wiring harness
View from left 8
Wiring harness
View from right 12
Technical data 3
Removing and installing instrument cluster 5
Dismantling and assembling instrument cluster
Technical data 3
Removing and installing headlight 5
Adjusting headlight 5
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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