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R 850 C
BMW R 850 C User Manual
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16.6
Removing and installing fuel
filter,
fuel pump and fuel leve
l sensor
e
Caution:
Fuel is flammable and a hazard to health.
Observe rel
evant safety reg
ulatio
ns.
•
Drain fuel
tank.
•
Remove fuel pump unit (1)
and detach hoses (2)
.
Removing and
installing
fuel
filter
•
Release hose clip
s at fuel filt
er (3).
e
Caution:
Note direction of fuel flow at
filter.
•
Secure n
on-reusab
le hos
e clips wi
th plie
rs,
BMW N
o.
13
1 500
.
C160020
5
1
3
2
4
125
127
Table of Contents
00 Maintenance and General Instructions
9
Default Chapter
9
Table of Contents
9
Maintenance and General Instructions
9
Tightening Torques
11
Table of Operating Fluids
17
Key to Maintenance Intervals
19
Reading out Moditec Fault Memory
19
(Inspections I, II, III and IV)
19
Checking Throttle Cable Play, Adjusting if Necessary
19
(Inspections I and III)
19
Changing Engine Oil, Renew Oil Filter Element
20
(Inspections I, II, III and IV)
20
Changing Oil in Gearbox
21
(Inspections III and IV) or at Least Every 2 Years
21
Changing Oil in Rear Wheel Drive; Cleaning Inductive Signal Transmitter at Rear Wheel
21
(Inspections I, III and IV)
21
Years
21
Renewing Fuel Filter
22
(Inspection III)
22
000 Km (12 000 Miles)
22
Checking Battery Acid Level/Topping up if Necessary, Cleaning/Greasing Battery Posts
24
(Inspections III and IV)
24
Renewing Intake Air Cleaner Element
24
(Inspection III)
24
Renewing Poly-V Belt
25
(Every 60 000 Km/36 000 Miles)
25
(Inspection III)
25
Poly-V Belt Adjusting Procedure
25
Checking Brake Fluid Level
26
Front Brake
26
Rear Brake
26
Checking Brake Pads and Discs for Wear/Renewing
27
(Inspections II and III)
27
Checking Front Brake Pad Wear
27
Checking Rear Brake Pad Wear
27
Checking Brake Disc Wear
27
Renewing Brake Pads Front Brake
28
Renewing Brake Padsrear Brake
28
Renewing Brake Fluid and Bleeding Brake System
29
Renew the Brake Fluid Annually
29
(Inspection IV)
29
[ABS Inspection II and III]
29
Bleeding Front Brake Circuit/Renewing Brake Fluid
29
Additionally with [ABS]
30
Bleeding Rear Brake Circuit/Renewing Brake Fluid
31
Additionally with [ABS]
32
Checking Clutch Operating Fluid Level
32
(Inspections I, II and III)
32
Checking Tightness of Rear Wheel Studs
33
Checking Rear Wheel Bearing Play by Tilting Wheel
33
(Inspection III)
33
Checking Swinging Arm Bearings, Adjusting if Necessary
33
(Inspections I and III)
33
Greasing the Side (Prop) Stand Pivot
33
(Inspections I, II and III)
33
Checking Function of Side (Prop) Stand Contact Switch
33
(Inspections I, II, III and IV)
33
Tightening Cylinder Heads
34
Checking/Adjusting Valve Operating Clearances
34
(Inspections I, II and III)
34
Checking/Renewing Spark Plugs
35
(Inspection II)/Renewing (Inspection III)
35
Check Synchronising
35
(Inspections I, II and III)
35
Final Inspection with Road Safety and Functional Check
36
(Inspections I, II, III and IV)
36
Road Safety Check
36
Roadworthiness Check
36
11 Motor
37
Technical Data
41
Sectioned Drawing of Engine
47
Lubricating Oil Circuit
48
Coolant Circuit
49
Removing Engine
51
Dismantling Engine
54
Removing Cylinder Head Cover
55
Locking the Engine in the TDC Position
56
Top Dead Centre on Ignition Stroke
56
Removing and Installing Chain Tensioner
57
Assembly Specification for Timing Chain Tensioner
57
Removing Valve Gear Holder
58
Dismantling/Reassembling Valve Gear Holder
59
Removing Cylinder Head
61
Dismantling, Checking, Repairing and Re-Assembling Cylinder Head
62
Removing and Installing Valves
62
Removing Valve Stem Seals
62
Checking Valves for Wear
63
Remachining Valve Seat
63
Checking and Repairing Cylinder Head
63
Checking Valve Guide for Wear
63
Replacing Valve Guides
64
Installing Valve and Valve Stem Seal
65
Removing Cylinder Barrel
66
Removing/Dismantling Piston
66
Checking Pistons and Cylinders
67
Assembling Pistons
67
Removing/Installing Conrod
68
Removing and Installing Alternator Cover with Engine Installed
69
Removing Alternator Mount Cover
69
Renewing Radial Shaft Seal in Alternator Mount Cover
70
Renewing Radial Shaft Seal for Rotary Breather
70
Removing Auxiliary Shaft Drive
71
Removing Oil Pump
72
Removing Radial Shaft Seal on Crankshaft with Engine Installed
73
Dismantling Crankcase
74
Removing Crankshaft, Auxiliary Shaft and Timing Chain Tensioning and Slide Rails
76
Removing and Installing Oil Pick-Up Basket
77
Replacing Oil Level Sight Glass
77
Removing Conrods
77
Checking Conrods
77
Measuring Main and Big End Bearing Play
78
Measuring Radial Bearing Play
78
Installing Main Bearing
79
Measuring Axial Bearing Play
79
Measuring Big End Bearing Play
80
Assembling Engine
81
Installing Conrod
81
Installing Crankshaft
82
Installing Timing Chain Tensioning and Slide Rails
82
Installing Auxiliary Shaft/Timing Chains
82
Assembling Engine Block
83
Installing the Crankshaft Radial Seal
85
Installing Clutch Housing
86
Installing Oil Pump
87
Installing Auxiliary Shaft Drive
88
Installing Piston
89
Installing Cylinder
90
Installing Cylinder Head
91
Adjusting Valve Clearances
92
Installing Right Cylinder Head
93
Adjustment Specification
93
Installing Left Cylinder Head
94
Adjustment Specification
94
Installing Alternator Mount Cover
96
Installing Magnetic Gate/Belt Pulley
96
Timing the Ignition
97
Installing Alternator
98
Installing Engine
99
12 Engine Electrics
101
Technical Data
103
Removing and Installing Coil and Ignition Lead
105
Check Ignition Coil Resistance
105
Removing and Installing Alternator
106
Poly-V Belt Adjusting Procedure
106
Dismantling/Reassembling Alternator
107
Checking Alternator
107
Checking Armature for Short to Ground (Earth)
107
Removing and Installing Starter Motor
108
Dismantling/Reassembling Starter Motor
109
Renewing Carbon Brushes
109
Checking Starter Motor
109
Checking Starter Relay
109
Removing and Installing Magnetic Gate
110
Timing the Ignition
111
13 Fuel Preparation and Control
113
Technical Data
115
Removing and Installing Air Cleaner
117
Removing and Installing Throttle Potentiometer
117
Removing and Installing Throttle Stub Pipe
117
Removing and Installing Injectors
118
Removing and Installing Throttle Positioner
118
Removing and Installing Throttle Potentiometer
118
Removing and Installing Motronic Control Unit
119
16 Fuel Tank and Lines
121
Technical Data
123
Removing and Installing Fuel Tank
125
Removing and Installing Fuel Filter
126
Removing and Installing Fuel Filter, Fuel Pump and Fuel Level Sensor
126
Removing and Installing Fuel Distributor and Pressure Regulator
127
Exhaust System
129
Removing and Installing Fuel Pump and Fuel Level Sensor
127
Checking Fuel Pump Pressure
127
21 Clutch
133
Technical Data
135
Installing Clutch
137
Removing and Installing Clutch
137
Removing Clutch
137
Removing and Installing Clutch Hydraulic Line
138
Removing and Installing Clutch Slave Cylinder
138
Filling/Bleeding Clutch Line
139
23 Gearbox
141
Technical Data
143
Removing Gearbox
145
Renewing the Shaft Sealing Rings in the Gearbox Housing and Gearbox Cover
147
Renew the Input Shaft Sealing Ring at the Input End
147
Renewing Output Shaft Sealing Ring
147
Renewing Input Shaft Sealing Ring at Output Side
148
Renewing Shaft Sealing Ring for Selector Drum
148
Renewing Sealing Ring for Selector Shaft
148
Removing and Installing Gear Pedal
145
Dismantling Gearbox
149
Removing Gearbox Housing
149
Removing Selector Drum
150
Dismantling/Assembling Selector Shaft
150
Removing Gearbox Shafts
151
Renewing Deep-Groove Ball Bearing on Intermediate Shaft
151
Dismantling/Assembling Input Shaft
152
Dismantling Input Shaft
152
Assembling Input Shaft
153
Dismantling/Reassembling Output Shaft
154
Stripping down Output Shaft
154
Assembling Output Shaft
155
Checking Endplay
156
Checking/Adjusting Fully Compressed Length of Gearbox Shafts, Selector Drum
157
Checking/Adjusting Fully-Compressed Length of Intermediate Shaft
157
Checking/Adjusting Fully-Compressed Length of Output Shaft
158
Checking/Adjusting Fully-Compressed Length of Input Shaft
159
Checking/Adjusting Fully-Compressed Length of Selector Drum
160
Shimming Selector Shaft
161
Assembling Gearbox
162
Installing Input, Output and Intermediate Shaft
162
Installing Selector Shaft
163
Installing Selector Drum
163
Assembling Gearbox Housing
164
31 Front Fork
167
Technical Data
169
Removing and Installing Telescopic Fork
171
Removing and Installing Fork Bridge
171
Removing and Installing Pot-Type Joints
172
Removing and Installing Ball Thrust Bearing
173
Removing and Installing Slider Tube Bridge
174
Removing and Installing Ball Joint
174
Checking Friction at Ball Joint/Ball Thrust Bearing
174
Assembly Specification for Telescopic Fork
175
Dismantling/Reassembling Telescopic Fork
176
Assembling Telescopic Fork
176
Dismantling Telescopic Fork
176
Measuring Telescopic Fork
177
Check Slider Tube Bridge
177
Checking Runout of Fixed Tube
177
Removing and Installing Leading Link
178
Removing and Installing Front Suspension Strut
178
Dismantling/Reassembling Leading Link
178
32 Steering
179
Technical Data
181
Removing and Installing Left Handlebar Fitting
183
Removing and Installing Right Handlebar Fitting
184
Removing and Installing Handlebar
185
Removing/Installing Throttle Cable
186
33 Rear Wheel Drive
187
Technical Data
189
Removing, Dismantling, Reassembling and Installing Rear Wheel Drive
191
Removing Rear Wheel Drive
191
Removing Input Bevel Pinion
191
Disassembling Input Bevel Pinion
193
Removing Needle Roller Bearing for Input Bevel Pinion
193
Installing Needle Roller Bearing for Input Bevel Pinion
193
Assembling Input Bevel Pinion
194
Installing Input Bevel Pinion
195
Removing and Dismantling the Crown Wheel
196
Assembling/Installing Crown Wheel
197
Checking/Adjusting Backlash
198
Checking Tooth Contact Pattern
199
Shimming Housing Cover
200
Installing Housing Cover
200
Installing Splined Element
200
Removing/Installing Rear Swinging Fork
201
Removing Rear Swinging Arm
201
Removing and Installing Taper Roller Bearing
202
Removing and Installing Flexible Gaiter
202
Removing Drive Shaft
202
Checking Universal Joint for Wear
202
Installing Drive Shaft
202
Installing Rear Swinging Arm
203
Installing Rear Wheel Drive
204
Removing and Installing Suspension Strut
205
34 Brakes
207
Technical Data
209
Removing and Installing Front Brake Caliper
211
Dismantling and Assembling Front Brake Caliper
212
Dismantling Front Brake Caliper
212
Assembling Front Brake Caliper
212
Removing and Installing Rear Brake Caliper
213
Dismantling and Assembling Rear Brake Caliper
214
Dismantling Rear Brake Caliper
214
Assembling Rear Brake Caliper
214
Removing and Installing Front Brake Disc
215
Removing/Installing Rear Brake Disc
216
Removing and Installing Front ABS Sensor
217
Adjusting Front ABS Sensor Gap
218
Marking Sensor Wheel
218
Checking and Adjusting Sensor Gap
218
Removing and Installing Rear ABS Sensor
219
Adjusting Rear ABS Sensor Gap
220
Marking Sensor Wheel
220
Checking and Adjusting Sensor Gap
220
Removing and Installing Rear Brake Master Cylinder
221
Checking and Adjusting Reliefclearance of Piston Rod
221
Removing and Installing Brake Pedal
221
Removing and Installing ABS Unit
222
Removing the ABS Unit
222
Installing the Abs Unit
223
Removing and Installing ABS Relay and Relay Base
224
Removing ABS Relay
224
Installing the ABS Relay
224
Removing ABS Relay Base
224
Installing the ABS Relay Base
225
Removing and Installing Brake Lines
226
Removing and Installing Front Brake Line
226
Removing and Installing Rear Brake Line
227
36 Wheels and Tyres
229
Technical Data
231
Installing Front Wheel
233
Removing and Installing Front Wheel
233
Removing Front Wheel
233
Removing and Installing Wheel Bearings
234
Removing/Installing Rear Wheel
236
Static Balancing of Front Wheel/Rear Wheel
237
Checking Front/Rear Wheel Rim for Runout
238
Centering Lateral Runout
239
Centering the Wheel Rim
239
Removing/Installing Spokes
239
46 Frame
241
Technical Data
243
Removing and Installing Rear Mudguard
245
Removing/Installing Front Mudguard
245
Removing and Installing Front Frame
246
Removing and Installing Rear Frame
248
Removing and Installing Side (Prop) Stand
250
Removing/Installing Footrest Supports
250
Checking Running Gear
251
Measuring Wheel Track Offset
251
Technical Data
263
Removing and Installing Central Electrical Equipment Box
265
Frame Wiring Harness
267
Wiring Harness
268
View from Left
268
Wiring Harness
272
View from Right
272
4
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BMW R 850 C Specifications
General
Brand
BMW
Model
R 850 C
Category
Motorcycle
Language
English
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