User manual BMW R 1200 C - REPAIR MANUAL

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. q The repair manual is structured in the logical sequence of the work to be performed: Removal, Dismantling, Repair, Assembly, Installation. q The entire contents are divided into individual chapters, corresponding to the Construction Groups. 11 . 10 Chap. Page number within chapter q 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. q 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 BMW Inspection at 1000 km (600 miles) BMW Inspection every 20 000 km (12 000 miles) 40 000 (24 000) 40 000 (24 000) 60 000 (36 000) ) BMW Service every 10 000 km (6 000 miles) 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) *) every 2 years 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) every 2 years 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 * 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 operation of brake system and freedom from leaks; repair/replace items if nec. *) *) 40 000 (24 000) 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 UX-VS-2, 06.99 Printed in Germany Order No. 01 71 0 008 872 BMW Annual Service BMW AG Motorcycle Division Pre-delivery check R 1100 S / R 850/1200 C / R 1150 GS Customer Licence plate No. BMW Pre-delivery check 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: Order No. 01 71 0 008 872 UX-VS-2, 06.99 Printed in Germany Contents Group / Chapter 00 Maintenance and general instructions 11 Motor 12 Engine electrics 13 Fuel preparation and control 16 Fuel tank and lines 18 Exhaust system 21 Clutch 23 Gearbox 31 Front fork 32 Steering 33 Rear wheel drive Group / Chapter 34 Brakes 36 Wheels and tyres 46 Frame 51 Equipment 52 Seat 61 General electrical equipment 62 Instruments 63 Lights 00 00 Maintenance and general instructions Contents Tightening torques Page ......................................................................................................................3 ...........................................................................................................9 ..............................................................................................11 ...............................................................................11 Table of operating fluids Key to maintenance intervals (Inspections I, II, III and IV) Reading out MoDiTeC fault memory Checking throttle cable play, adjusting if necessary ..............................................................................................................11 (Inspections I and III) Changing engine oil, renew oil filter element (Inspections I, II, III and IV) .............................................................12 Changing oil in gearbox (Inspections III and IV) or at least every 2 years ..........................................................................................................13 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: .........................................................................................................18 Checking brake fluid level Front brake 00.1 Contents Rear brake Page Checking brake pads and discs for wear/renewing (Inspections II and III) ......................................................19 Checking front brake pad wear ..............................................................................................19 Checking rear brake pad wear ................................................................................................19 Checking brake disc wear ........................................................................................................19 ........................................................................................20 Renewing brake pads Front brake Renewing brake padsRear brake Renew the brake fluid annually (Inspection IV) [ABS Inspection II and III] ..........................................................................................20 Renewing brake fluid and bleeding brake system ...................................................21 Bleeding front brake circuit/renewing brake fluid Additionally with [ABS] ...........................................................21 Bleeding rear brake circuit/renewing brake fluid Additionally with [ABS] ............................................................23 Checking clutch operating fluid level (Inspections I, II and III) .............................................................................24 Checking tightness of rear wheel studs (Inspection I) ........................................................................25 Checking rear wheel bearing play by tilting wheel (Inspection III) .................................................25 Checking swinging arm bearings, adjusting if necessary (Inspections I and III) ...................................25 Greasing the side (prop) stand pivot (Inspections I, II and III) ................................................................................25 Checking function of side (prop) stand contact switch (Inspections I, II, III and IV) ........................................25 Tightening cylinder heads (Inspection I) .....................................................................................................26 Checking/adjusting valve operating clearances (Inspections I, II and III) ......................................................26 Checking/renewing spark plugs (Inspection II)/renewing (Inspection III) ........................................................................................27 Check synchronising (Inspections I, II and III) ................................................................................................................27 Final inspection with road safety and functional check (Inspections I, II, III and IV) Road safety check Roadworthiness check .......................................28 00.2 00 Tightening torques Model Connection 11 Engine Cylinder head Tightening sequence: 1. Tighten cylinder head nuts (oiled) crosswise 1.1 Tighten all nuts to correct torque for joint 1.2 Tighten all nuts to correct angle 1.3 Tighten all nuts to correct angle 2. M 10 bolt 3. M 6 screw After 1000 km (600 miles), tighten cylinder head nuts crosswise: 1. Unfasten one nut 2. Tighten one nut to initial value 3. Tighten nut to wrench angle 4. Unfasten/retighten M10 screw Timing gear carrier to cylinder head Bearing cap on rocker shaft Locknut, valve adjusting screw Cylinder head cover to cylinder head Camshaft end cover to cylinder head Air intake connection to cylinder head Camshaft Chain sprocket to camshaft Camshaft bearing cap Rotary breather Vent line to alternator mount cover M 8 screw Banjo screw Alternator mount cover M 6 screw M 8 screw Auxiliary shaft Chain sprocket to crankshaft Chainwheel to auxiliary shaft Chain tensioner housing to engine block 10 70 9 9 20 20 25 65 15 180° 40 9 15 8 9 9 9 20 90° 90° 40 9 20 R 850/1200 C Nm 00.3 Model Connection 11 Engine Oil filter Oil filter Oil drain plug Oil pump Mesh filter basket to engine block Oil pump cover Pressure relief valve Oil pressure switch Oil cooler Oil cooler pipe to engine block Cooling oil line - banjo screw with oil vent valve Oil cooler to frame Oil cooler return line to engine block Screw-in union for oil cooler connection at engine block Cylinders Tightening sequence: 1. M 8 screw 2. M 6 screw 3. Chain guide rail pivot screw Timing chain Chain tensioner Connecting rod Big end cap Joint torque Additional wrench angle Crankcase Tightening sequence: 1. M10 screw (oiled) 2. M 8 screw (oiled) 3. M 6 screw 80° R 850/1200 C Nm 11 32 9 9 35 30 10 25 9 35 35 (clean threads and apply Loctite 603 to inner and outer threads and in the contact face area) 20 9 18 32 20 45 20 9 00.4 Model Connection 12 Engine electrics Starter motor to engine Starter cover to housing Positive lead to starter motor Alternator to cover mount Tensioning and retaining strap at alternator Spacer at alternator Positive lead to alternator Belt pulley at alternator Belt pulley to crankshaft Poly-V belt preload Spark plug Ignition coil holder to frame 13 Fuel preparation and control Oil temperature sensor to engine block Air temperature sensor to air cleaner cover 16 Fuel tank and lines Fuel tank to rear frame 18 Exhaust system Manifold to cylinder head Clip on muffler Oxygen sensor (lambda probe) to muffler 21 Clutch Clutch housing Joint torque Additional wrench angle Housing cover Slave cylinder to gearbox Clutch line to handlebar fitting 32° R 850/1200 C Nm 20 7 10 20 20 20 15 50 50 8 20 9 25 10 10 24 55 (apply Never Seez to clip contact surface) 45 (apply Never Seez to thread) 40 (oil screw threads lightly) 12 9 18 00.5 Model Connection 23 Transmission Oil filler plug Oil drain plug Gearbox to engine block Gear shift pedal to rear frame Selector lever to selector shaft Gearbox cover to gearbox housing 31 Front fork Fixed tube to fork bridge Slider tube bridge to slider tube Quick-release axle clamp screws Threaded journal to frame Ball joint to fork slider bridge Leading link to ball joint Leading link to engine Screw cap at leading link Spring strut to frame Spring strut to leading link 32 Steering Handlebar at fork bridge Twistgrip to handlebar 33 Rear wheel drive Oil filler plug Oil drain plug Threaded ring Hexagon nut, input bevel gear Cover at rear-wheel drive housing Rear-wheel drive to swinging arm Swinging arm bearing journal to rear frame Swinging arm bearing journal to rear frame Locknut at swinging arm bearing journal Suspension strut to rear frame Suspension strut to rear swinging arm R 850/1200 C Nm 23 55 22 41 9 9 35 (free from oil and grease) 22 (clean thread + Loctite 243) 20 130 (clean thread + Loctite 243) 230 (apply light coat of Never Seez to thread) 130 (clean thread + Loctite 2701) right 73 left 42 (apply light coat of Never Seez to thread) 40 40 21 (apply light coat of Never Seez to thread) 8 23 23 118 (Hylomar SQ 32 M) 200 (clean thread + Loctite 2701) 35 24 right 9 left 7 (clean thread + Loctite 2701) 160 50 50 00.6 Model Connection 34 Brakes Brake caliper at fork slider tube Brake caliper to rear wheel drive Brake disc to front wheel 34 Brakes Brake disc to rear wheel drive Master cylinder to footrest assembly Brake pedal to footrest assembly Brake lines/brake hose to brake components ABS sensor Front brake caliper bleed screw Rear brake caliper bleed screw Pressure modulator bleed screw 36 Wheels and tyres Quick-release axle clamp screws Quick-release axle threaded connection Rear wheel to rear wheel drive Screw wheel studs in handtight, then tighten in a crosswise pattern Initial tightening Final tightening R 850/1200 C Nm 40 40 24 (clean thread + Loctite 2701) 21 (clean thread + Loctite 2701) 8 37 18 4 (handtight) 7 4 9 20 30 50 105 00.7 Model Connection 46 Frame Frame to engine M12 pin M10 screw Rear frame to engine to gearbox Side (prop) stand pivot mount to engine Side (prop) stand to pivot mount Footrest assembly to engine M12 screw M8 screw Pillion footrest holder to rear frame Pillion seat mount Mudguard to slider tube bridge 51 Equipment Mirrors Ignition/steering lock to fork bridge 61 General electrical equipment Horn to holder Ground (earth) strap to engine block 63 Lights Headlight to holder R 850/1200 C Nm 82 58 41 71 21 42 (clean thread + Loctite 243) 71 21 21 21 8 15 15 (shear bolt) 13 10 15 00.8 Table of operating fluids Item Lubricant Use Order number Quantity Optimoly MP 3 Optimoly TA Silicone grease 300, heavy Retinax EP2 Contact spray Chain spray Sealants High-performance lubricating paste High-temperature assembly paste Damping grease 07 55 9 062 476 100 g tube 18 21 9 062 599 100 g tube 07 58 9 058 193 10 g tube Wheel, steering head and taper roller 83 22 9 407 845 100 g tube bearing grease Contact spray Drive chain 81 22 9 400 208 300 ml aerosol 72 60 2 316 676 50 ml spray 72 60 2 316 667 300 ml spray 3-Bond 1110 B 3-Bond 1209 omni VISC 1002 Loctite 574 Curil K 2 Hylomar SQ 32 M Adhesives and retaining agents Loctite 648 Loctite 638 Loctite 243 Loctite 270 Loctite 2701 Loctite 454 Cleaner Surface sealant Surface sealant Surface sealant Surface sealant Heat-conductive sealant Permanently elastic sealant 07 58 9 056 998 5 g tube 07 58 9 062 376 30 g tube 07 58 1 465 170 90 g tube 81 22 9 407 301 50 ml tube 81 22 9 400 243 250 g can 81 22 9 400 339 100 g tube Joint adhesive (low clearance) Joint adhesive (greater clearance) Thread retainer, medium-strength Thread retainer, strong Thread retainer, strong Cyanacrylate adhesive (gel) 07 58 9 067 732 5 g bottle 07 58 9 056 030 10 ml bottle 07 58 9 056 031 10 ml bottle 81 22 9 400 086 10 ml bottle 33 17 2 331 095 10 ml bottle 07 58 9 062 157 20 g tube Brake cleaner Metal Polish Testing agent Brake cleaner Polish for chromium plated parts 83 11 9 407 848 600 ml aerosol 82 14 9 400 890 100 g tube Penetrant MR 68 Entwickler MR 70 Crack testing agent for aluminum housings Crack testing agent for aluminum housings 83 19 9 407 855 500 ml spray 81 22 9 407 495 500 ml spray 00.9 00.10 Key to maintenance intervals ­ ­ ­ ­ BMW Inspection 1000 km/600 miles BMW Service BMW Inspection BMW Annual Service Checking throttle cable play, adjusting if necessary (Inspections I and III) I II III IV · · · Reading out MoDiTeC fault memory (Inspections I, II, III and IV) 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. · · · · Remove the left air cleaner trim panel. Connect MoDiTeC to diagnostic plug. Read out the fault memory. Perform any repair work indicated. 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) · · Unscrew oil drain plug and drain off oil. Fit new seal and screw in drain plug. 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. 11 4 650 C000030 · · · · · C000240 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. e Caution: X Never add engine oil above the MAX mark. · Remove screw plug. 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 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 (Inspections III and IV) or at least every 2 years · Change the gearbox oil while at regular operating temperature. · Change the gearbox oil while at regular operating temperature. 2 1 3 5 6 4 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. C000050 e Caution: · · · · · · · Note that the interior of the gearbox is slightly pressurised. 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. 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. 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 X 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) · · Pull the plug connector off the fuel pump assembly. Lift off fuel tank. · · · 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. 00.14 2 1 C160020 · · · Drain fuel tank. Remove fuel pump assembly. Detach hoses from fuel filter (1). X pump unit .............................................. 5 Nm Tightening torque: Fuel Installing: e Caution: · · Note correct direction of flow through fuel filter. Use only an O-ring seal (2) in good condition. After installing, check fuel pump assembly for leaks. Fit new fuel filter. Secure non-reusable hose clips with pliers, BMW No. 13 1 500. L Note: path of vent lines. Note correct 00.15 C000020 Checking battery acid level/topping up if necessary, cleaning/greasing battery posts (Inspections III and IV) Renewing intake air cleaner element (Inspection III) In very dirty and dusty operating conditions, renew every 10 000 km (6 000 miles) or even more frequently if necessary · · · 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 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. Tightening torque: Fuel tank to rear frame ................................. 10 Nm X 00.16 Renewing Poly-V belt (every 60 000 km/36 000 miles) (Inspection III) 3 12 3 510 4 1 RS110480 2 · C000060 Slacken off alternator mounting screws (1,3,4) and install a new Poly-V belt if necessary. · · · 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. 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. TDC 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 1 C000070 e Caution: Install the vent line with new O-ring seals. · · · Remove the horn with its mount. Remove front cover. Remove vent line (1). 00.17 Checking brake system for correct operation and freedom from leaks; repairing/renewing if necessary (Inspection III) Rear brake · · Position the motorcycle horizontally with auxiliary stand, BMW No. 00 1 550. Brake fluid must not drop below the minimum level (arrow). · Checking brake system for leaks. Checking brake fluid level L brake fluid volume (between MIN and MAX) is Note: The 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. C000090 (Inspections I, II and III) Brake fluid grade .........................................DOT 4 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 00.18 Checking brake pads and discs for wear/renewing (Inspections II and III) Checking rear brake pad wear Checking front brake pad wear C000120 It should not be possible to see the brake disc through the hole (arrow) in the inner brake pad. C000100 If the brake disc is visible, the wear limit has been reached and the pads must be renewed. Checking brake disc wear C000110 · Examine the wear limit marks (arrows). e Caution: C000130 Brake pad thickness must not fall below the minimum value. Change pads only as a complete set. · Examine the brake discs carefully for cracks, damage, distortion, wear and score-marks. Minimum lining thickness: .......... 1.5 mm (0.06 in) Brake disc wear limit: front:........................................... 4.5 mm (0.177 in) rear:............................................ 4.6 mm (0.181 in) 00.19 Renewing brake pads Front brake Renewing brake pads Rear brake C000100 C000140 · Detach/remove brake caliper from mounting (arrow). · · · · · · · 1 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. 2 C000230 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 X · · · · · 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: tube.................... 40 Nm Brake caliper at fork slider 00.20 Renewing brake fluid and bleeding brake system Renew the brake fluid annually (Inspection IV) [ABS Inspection II and III] · · · 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. 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. e Caution: the brakes, always start on the right When bleeding side. KR340280 e Caution:brake fluid, do not allow it to enter the When adding holes for the reservoir lid screws. · · Take off the brake caliper. Remove the brake pads. · · · · · · 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: 34 1 500