BMW R 850 RT 2004 Maintenance Instruction

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Maintenance Instructions (US Model)

R 850 RT

R 1150 RT

BMW Motorrad

On-board

documentation

consisting of

Rider's Manual

and Maintenance

Instructions

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Summary of Contents for BMW R 850 RT 2004

Page 1 Maintenance Instructions (US Model) R 850 RT R 1150 RT BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad On-board On-board...
Page 2 Please note This symbol indicates pre- cautions and measures which are essential in pro-tecting the rider or other persons from severe or fatal injury. Specific instructions and safety precautions intended to pre- vent damage to the motorcycle. Disregarding them may render the warranty invalid.
Page 3: Bmw Motorrad
Please contact your authorized Your authorized BMW motorcy- BMW motorcycle retailer if you cle retailer is the best place to have any questions regarding keep you informed as to current your motorcycle.
Page 4: Important Safety Information
BMW cannot assess every sin- gle product of outside origin in order to decide whether it can be used on or with a BMW vehi- cle without constituting a safety hazard. Nor is approval by an official...
Page 5: Maintenance Work
Maintenance work is divided into Service, Inspection and Annual Inspection. BMW Inspection 600 miles (1,000 km) BMW Break-in Check after the first 600 miles (1,000 km). BMW Service After the first 6,000 miles (10,000 km) and every addi- tional 12,000 miles (20,000 km)
Page 6: Confirmation Of Maintenance Work
Confirmation of maintenance work BMW Service Pre-Delivery Check 6,000 miles (10,000 km) Performed in accordance with Performed in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection BMW Inspection 600 miles (1,000 km)
Page 7 Confirmation of maintenance work BMW Service BMW Service 18,000 miles (30,000 km) 30,000 miles (50,000 km) Performed in accordance with Performed in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection...
Page 8 Confirmation of maintenance work BMW Service BMW Service 42,000 miles (70,000 km) 54,000 miles (90,000 km) Performed in accordance with Performed in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection...
Page 9 Confirmation of maintenance work BMW Service BMW Service 66,000 miles(110,000 km) 78,000 miles (130,000 km) Performed in accordance with Performed in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection BMW Inspection...
Page 10 Confirmation of maintenance work BMW Service BMW Service 90,000 miles (150,000 km) 102,000 miles (170,000 km) Performed in accordance with Performed in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection...
Page 11 Confirmation of maintenance work BMW Service BMW Service 118,000 miles 130,000 miles (190,000 km) (210,000 km) Performed in accordance with Performed in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection...
Page 12 Performed in accordance with Performed in accordance with manufacturer’s instructions manufacturer’s instructions Brake fluid changed: Brake fluid changed: Without BMW Integral ABS Without BMW Integral ABS annually annually With BMW Integral ABS With BMW Integral ABS Wheel Circuit - annually...
Page 13 Performed in accordance with Performed in accordance with manufacturer’s instructions manufacturer’s instructions Brake fluid changed: Brake fluid changed: Without BMW Integral ABS Without BMW Integral ABS annually annually With BMW Integral ABS With BMW Integral ABS Wheel Circuit - annually...
Page 14: Confirmation Of Service
Confirmation of service Record of all work performed in workshop Work performed km/mile Date The list is intended as a record of maintenance, warranty and repair work, the installation of optional accessories and, if appro- priate, special campaign work.
Page 15 Confirmation of service Record of all work performed in workshop Work performed km/mile Date The list is intended as a record of maintenance, warranty and repair work, the installation of optional accessories and, if appro- priate, special campaign work.
Page 16 Confirmation of service Odometer replaced Odometer replaced Odometer reading is not total Odometer reading is not total distance covered. distance covered. Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature Odometer replaced Odometer replaced Odometer reading is not total Odometer reading is not total distance covered.
Page 17: General Instructions
General instructions Your motorcycle is equipped with Digital Motor Electronic (MOTRONIC) engine manage- ment and a high-power ignition system. If you intend to perform the maintenance and general care work described in the following When the engine is running or section yourself, you must pos- the ignition is switched on, do sess the necessary knowledge...
Page 18 Keep to the specified Inspec- Authorized BMW motorcycle tion and Service intervals. retailers have the necessary technical know-how and spe- BMW refuses to accept liability cially trained staff. for damage or consequential They can guarantee that your damage due to repairs or ser-...
Page 19: Technical Modifications
The motorcycle must not infringe your national road- vehicle construction and use regulations. Your authorized BMW motorcy- Technical modifications cle retailer will gladly advise you on technical requirements, the manufacturer’s recommenda- tions and the overall benefit The data stored in the likely to be obtained.
Page 20: Troubleshooting Chart
Troubleshooting chart Malfunction: Engine does not start at all or is very difficult to start Possible cause Remedy Page Wrong ignition key Operate correctly Rider’s Manual position Kill switch on Operate correctly Rider’s Manual Side stand out and Operate correctly Rider’s Manual gear engaged Power supply...
Page 21 More detailed technical infor- 15 to 59 – take your motorcycle mation is available in the follow- to a BMW-certified workshop, ing publications: preferably an authorized BMW – BMW Repair Manual motorcycle retailer, to be –...
Page 22: Removing Front Wheel
Removing front wheel When removing, avoid damage to brake lines, brake disks, brake pads or the wheel rim (mask off with tape if necessary). • Place the motorcycle on its Keep dirt and moisture away main stand on a flat, firm from the wheel bearings.
Page 23 Removing front wheel Do not scratch the rim when forcing back the brake pads or removing the calipers (apply masking tape if necessary). To prevent damage to the brake • Unscrew the retaining bolts 4 caliper and possible difficulty for the left/right brake calipers when assembling: never apply •...
Page 24 Removing front wheel • Remove speedometer drive 4 and spacer bush 3 • Roll the front wheel forward and out • Remove axle bolt 5 • Slacken off axle clamp bolts 1 on the left and right When setting down the front •...
Page 25: Installing Front Wheel
Installing front wheel • Roll the front wheel in between the fork stanchions Avoid damage to brake lines, disks and pads when installing. To prevent the speedometer Keep dirt and moisture away shaft from being damaged, the from the wheel bearings. nose A on the slide tube must Do not damage the ABS sensor be inserted in the notch B on...
Page 26 Installing front wheel • Clean the quick-release axle, • Tighten axle clamp bolts 2 on 1, grease it, and insert it from the left/right to their tightening the right, turning slightly at the torque same time • Mount left and right brake cal- •...
Page 27 Installing front wheel Always have the tightening torques checked by a BMW- certified workshop, preferably by an authorized BMW motorcycle retailer. Watch spacer bushings. • Install the front mudguard 3 Once the brake calipers have • Insert mounting bolts 1 and 2...
Page 28: Removing Rear Wheel
Removing rear wheel • Place the motorcycle on its main stand on a flat, firm sur- face ( Rider's Manual, Chapter 3). • Apply a load at the front wheel so that the motorcycle cannot tip toward the rear When removing, avoid damage •...
Page 29 Removing rear wheel • Unscrew brake caliper bolts 4 • Push the brake pads back Do not scratch the wheel when slightly by lightly rocking the forcing back the brake pads or brake calipers removing the caliper (apply • Carefully take off the brake masking tape if necessary).
Page 30 Removing rear wheel • Remove the four wheel studs 1 with taper rings 2 • Lift the rear wheel off the cen- tering spigot and carefully roll Protect the wheel hub contact it out to the rear face against dust and dirt. •...
Page 31: Installing Rear Wheel
Installing rear wheel • Check that the wheel center- ing and contact surfaces for the wheel hub and the shim are free of grease • Push shim 3 onto the wheel Use only wheel studs with the centering spigot same length code number. Do •...
Page 32 Installing rear wheel Always have the tightening torques checked by a BMW- • Carefully place brake caliper 1 certified workshop, preferably over the brake disk an authorized BMW motorcycle retailer. Ensure that retaining bracket Tightening torque: A is positioned correctly.
Page 33 Installing rear wheel Once the brake calipers have been completely installed and the ignition has been switched on, and successful • Install rear wheel cover 3 with self-diagnosis has been per- bolts 1 and 2 formed, the foot brake and •...
Page 34: Checking Brake Pads
For your safety, we recommend must be clearly visible on having work on the brake the brake pads. system performed by a BMW- – If the wear indicating mark is certified workshop, preferably no longer clearly visible: an authorized BMW motorcycle have the brake pads retailer.
Page 35: Rear Brake
1 in the inner For your safety, we recommend brake shoe: having work on the brake have the brake pads system performed by a BMW- changed by a BMW-certi- certified workshop, preferably fied workshop, preferably an authorized BMW motorcycle an authorized BMW motor- retailer.
Page 36: Removing Side Panel
Removing side panel 11 10...
Page 37 Removing side trim • Place motorcycle on main (center) stand • Remove system case • Take off complete two-sec- tion dualseat • Remove bolt 9 and take off side section 8 • Carefully pull off turn indica- tor/mirror housing and hold •...
Page 38: Notes On Changing Bulbs
Notes on changing bulbs Your motorcycle is equipped with one bulb for each of low beam headlamp, high beam headlamp, parking light, brake light and rear light, two bulbs for the fog lamp and four bulbs for Your motorcycle is equipped the indicators.
Page 39: Changing Bulbs
Changing bulbs Rear/brake light, rear turn indicators • Place motorcycle on main (center) stand Switch off the ignition before • Take off the rear seat changing a bulb. • Unscrew and remove the two knurled nuts 1 • Take off the combined turn indicator/rear light assembly The dimmed brake light takes •...
Page 40: Front Turn Indicators
Changing bulbs Front turn indicators • Press bulb 2 into socket and disengage by turning counter-clockwise. Switch off the ignition before • Remove the bulb changing a bulb. • Assembly is performed in reverse order • To ease installation of the turn indicator/mirror housing, grease the retaining clips Do not touch the glass of new...
Page 41 Changing bulbs Parking light • Place motorcycle on main (center) stand Switch off the ignition before • Pull bulb holder 1 downwards changing a bulb. out of the headlight casing • Remove bulb 2 by pressing it in and turning it counter- clockwise at the same time Do not touch the glass of new •...
Page 42 Changing bulbs Low beam headlamp Do not touch the glass of new bulbs with your fingers. Use a Switch off the ignition before clean, dry cloth to hold the changing a bulb. bulbs when inserting them.
Page 43 Changing bulbs • Release the retaining clip 3 from its catch 4 by pushing down and squeezing together at the same time • Place motorcycle on main • Remove the bulb 5 (center) stand • Installation is the reverse of •...
Page 44: High Beam Headlamp
Changing bulbs High beam headlamp: – High beam headlamp: H3 12 V 55 W • Place the motorcycle on its main stand on a flat, firm surface • Push the clip 1 upwards Switch off the ignition before (arrow) changing a bulb. •...
Page 45 Changing bulbs • Use a screwdriver to push in 1 retaining lug 6 on the left and one on the right and take apart the bulb socket • Pull the H3 bulb out of the lamp ring 8 • Installation is the reverse of When assembling the bulb the removal procedure socket, align the slot 10 on the...
Page 46 Changing bulbs Foglamp • Place the motorcycle on its main stand on a flat, firm Switch off the ignition before surface changing a bulb. • Remove the rubber cover 4 • Release the retaining clip 2 by pressing down and squeezing together at the same time Do not touch the glass of new •...
Page 47 Changing bulbs • Insert the new bulb 5, taking care to ensure that the slot 2 is pointing to the rear • Insert the plug-in cable 7 into • Click the retaining clip 4 into the socket housing 1 its catch 3 •...
Page 48 Fuses Fuse assignment 1 Instrument cluster ..4 A 2 Parking light, ABS ..4 A 3 Power sockets, RID, radio, optional equipment plug, windshield adjustment ...15 A 4 Horn ......7.5 A 5 Motronic, RID, Motronic Before changing a fuse, switch relay, diagnosis plug..10 A off the ignition.
Page 49: Replacing Fuses
• Insert a new fuse of the cor- If the electrical system often rect rating displays faults, have it checked • Close the lid of the central by a BMW-certified workshop, electrical equipment box preferably by an authorized • Close and lock the seat BMW motorcycle retailer.
Page 50: Air Filter
Air filter • Remove the old filter cartridge 6 from the air filter housing • Place the new filter element in position inside the air filter Replacing air filter housing element • Installation is the reverse of • Place the motorcycle on its the removal procedure main stand •...
Page 51: Battery Safety Instructions
Battery safety instructions Gel batteries are maintenance- The motorcycle must not be free. Compliance with the fol- jump-started using the power lowing instructions is important socket. for achieving a long battery life: – Risk of fire! • Push-start the motorcycle only when the engine is cold.
Page 52: Battery Maintenance Instructions
In case of doubt ask a completely drained. In this specialist, preferably an case, warranty claims will not authorized BMW motorcycle be accepted. retailer, to prepare the vehicle Disconnect the ground cable for storage and to carry out the...
Page 53: Removing Battery
Battery • Place the motorcycle on its main stand • Remove the dualseat • Remove the left-hand side trim ( Removing battery • Remove the air filter cover • Remove the air intake pipe 1 Avoid damage to fuel tank, wiring and hoses during removal work.
Page 54 Battery • Release the battery retaining • Open the protective cap on clip 3 the battery positive pole 5 • Disconnect the negative bat- using a screwdriver tery lead (–) 4 • Disconnect the positive bat- • Pull out the battery to the left tery lead (+) 6 and hold it horizontally •...
Page 55: Installing Battery
Battery • Installation is the reverse of the removal procedure Installing battery Disconnecting the battery deletes all entries (e.g. faults, settings) stored in the Motronic Before connecting the bat- control unit's memory. tery, switch off the ignition. Loss of settings can temporarily To avoid short-circuits: impair the operating •...
Page 56 Cleaning/care Aggressive or deep-action cleaning products and solvents should not be used to clean rubber and plastic parts; they may cause damage. Regular cleaning using the cor- Do not use a steam jet or high- rect methods is an important pressure cleaning equipment.
Page 57 • Thoroughly dry all wet • Treat painted and chrome- surfaces plated surfaces regularly with • Use only BMW care products the approved care products to clean trim parts • Do not use solvents or clean- ing products to wash the...
Page 58 Cleaning/care Removing road salt • Wash the motorcycle down Cleaning the windshield immediately with cold water at • Remove dirt and dead insects the end of the journey with a soft sponge and plenty of water Do not use warm water – this aggravates the effect of the salt Soften stubborn dirt or insects by soaking with a wet paper...
Page 59 More extensive damage should be attended to by a BMW- certified workshop, preferably Touching up paint damage an authorized BMW motorcycle • Use a BMW paint pen to retailer. repair minor damage to the paint work Care of muffler • Use Autosol “Metal Polish”...
Page 60 Before storing the vehicle have 54-57) the engine oil and the oil filter • Remove the battery ( 51-52) element changed by a BMW- • Spray the clutch lever pivots certified workshop, preferably and the main and side stand your authorized BMW pivots with a suitable lubricant motorcycle retailer.
Page 61: Returning To Use
Returning to use • Check/correct tire pressures Returning to use Rider's Manual, Chapter 2) • If necessary, remove • Check the brakes protective wax coating Rider's Manual, Chapter 2) • Clean the motorcycle ( • Carry out safety checks • Install a charged battery Rider's Manual, Chapter 2, 3)
Page 62 Engine R 1150 RT R 850 RT Type Two-cylinder, air-cooled boxer engine with additional oil-cooled outlet, chain-driven side camshaft 4 bucket tappet/push rod-operated valves/cylinders, wet sump lubrication. Displacement 1,130 cm 848 cm Maximum rated output in accordance with DIN 70 020 70 kW 54 kW - at engine speed...
Page 63 Transmission R 1150 RT R 850 RT Clutch Lightweight single-plate dry clutch mounted on crankshaft, with increased-leverage diaphragm spring and starter gear ring. Hydraulic actuation Clutch plate dia. 6.5 in (165 mm) Transmission 6-speed with claw shift and integral torsional vibration damper Gear ratios 1st gear = 3.863 2nd gear = 3.022...
Page 64: Frame And Suspension
Frame and suspension R 1150 RT R 850 RT Frame New, 3-part chassis design. The self-supporting engine and transmission unit is connected to a rear frame made from steel tubing via a front frame made from cast aluminum. Location of type plate and frame number On right of front frame section Front brake...
Page 65 Frame and suspension R 1150 RT R 850 RT Wheel location Front Quick-response wheel control (Telelever) with central spring strut. Rear Single tubular cast-aluminum swinging arm with additional torque arm for compensating car- dan reactions (Paralever) with cen- tral spring strut. Steering lock angle of front wheel 2 x 34°...
Page 66 Frame and suspension R 1150 RT R 850 RT Front suspension Central strut with linear-rate coil spring (with taper-wound ends) and twin-tube, gas-filled shock absorber. Spring compression 2.56 in (65 mm) Spring extension 2.17 in (55 mm) Total travel 4.72 in (120 mm) Fixed tube diameter 1.38 in (35 mm) Rear suspension...
Page 67 Frame and suspension R 1150 RT R 850 RT Wheels and tires BMW cast aluminum wheels with 5 double spoke design, low cross-section tires Front wheel Angled rim shoulder and double tire retaining hump Size and designation 3.50 x 17 MT H2...
Page 68: Lubricants And Operating Materials
“Special Oils” are approved individually by BMW AG and avail- able from your authorized BMW motorcycle retailer. All engine oils supplied by BMW are subject to regular BMW quality assurance checks. BMW does not approve the use of any upper-cylinder lubricants or similar oil additives.
Page 69 Lubricants and operating materials R 1150 RT R 850 RT Gear oil Brand-name hypoid gear oil, API class GL 5 Capacity Transmission approx. 0.85 quarts (0.8 l) (up to lower edge of filler opening) Rear wheel drive (after approx. 0.26 quarts (0.25 l) stripping down) (up to lower edge of filler plug) Viscosity class...
Page 70 – 13 °F to 284 °F (-25 °C ...+120 °C), drip point 374 °F (190 °C), high corrosion protection, good resistance to water and oxidation; e.g. Shell Retinax EP2 Brake fluid DOT 4 We recommend BMW brake fluids Use only new brake fluid to DOT 4 specification.
Page 71: Electrical System
Electrical system R 1150 RT R 850 RT Spark plugs Approved makes/types Primary spark plug NGK BKR 7 EKC Secondary spark plug Bosch YR6LDE or NGK DCPR 8 EKC +/-0.1 +/-0.1 Electrode gap 0.031 in (0.8 mm ) Wear limit 0.04 in (1.0 mm) Fuses “Minifuse”...
Page 72: Dimensions And Weights
Dimensions and weights R 1150 RT R 850 RT Overall length 87.8 in (2,230 mm) Width across mirrors 35.35 in (898 mm) - over handlebar ends (with 30.43 in (773 mm) vibration dampers) across front footrests 23.5 in (597 mm) across rear footrests 26.77 in (680 mm) Overall height (excl.
Page 73: Performance Data
Performance data R 1150 RT R 850 RT Top speed acc. to type approval test 124 mph (200 km/h) Flexibility 4th gear 50-75 mph 3.57 s 4.22 s (80-120 km/h) 5th gear 50-75 mph 4.49 s 5.27 s (80-120 km/h) 6th gear 50-75 mph 6.78 s 8.39 s...
Page 74 A – E Cleaning/care Air filter, 48 Cleaning, 55 Annual service, notes, 3 General instructions, 54, 56 Paint damage, 57 Road salt, 56 Battery Clutch, 61 Charging, 49 Compression ratio, 60 Installing, 53 Confirmation of maintenance work Removing, 51 Annual service, 11 Warranty, 49 Inspection, 4, 5, 6, 8, 9 Bore/stroke, 60...
Page 75 F – R Maximum speed, 60 Flexibility, 71 Motorcycle Foglamp, 44 Returning to use, 59 Frame, 62 Storing, 58 Front wheel Installing, 23, 24, 25 Odometer replacement, Removing, 20, 21, 22 confirmation, 14 Technical Data, 65 Oil capacity Fuel Engine, 66 Consumption, 60 Manual transmission, 67 Type, 67...
Page 76 S – Z Transmission Safety information, 2 Capacity, 67 Safety instructions Gear ratios, 61 Explanation, 78 Oil types, 67 Safety precautions, 15, 36 Technical Data, 61 Seat height, 70 Tread depth, 65 Service, notes, 3 Troubleshooting, 18 Spark plugs, 69 Troubleshooting chart, 18 Speedometer drive, 23 Type plate, 62...
Page 78 Motorcycle data Model Frame No. Color No. First registered on Registration No. Retailer data Person to contact for Service work Ms./Mr. Tel. No. Retailer’s address with telephone No. (company stamp)
Page 79 No claims will be Errors and omissions excepted. considered as a result of such © 2004 BMW Motorrad discrepancies. Not to be reproduced either wholly Dimensions, weights, fuel or in part without written permis-...
Page 80 BMW recommends Castrol BMW Motorrad Printed information Order No.: 01 47 7 693 607 05.2004 The Ultimate 4th edition US / RF Driving Machine...

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BMW R 850 RT 2004 Maintenance Instruction

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