BMW R 850 R Comfort Maintenance Instruction

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Repair manual (464 pages)

Rider's manual (92 pages)

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Maintenance Instructions

R 850 R Comfort

BMW Motorrad

On-board

documentation

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Rider's Manual

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Instructions

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Summary of Contents for BMW R 850 R Comfort

Page 1 Maintenance Instructions R 850 R Comfort 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 BMW Motorrad BMW Motorrad On-board On-board...
Page 2 Please note Warning: This symbol indicates precau- tions and measures which are essential in protecting the rider or other persons from severe or fatal injury. Attention: Specific instructions and safety precautions intended to prevent damage to the motorcycle. Disre- garding them may render the war- ranty invalid.
Page 3 Important: and will gladly advise and assist BMW refuses to accept liability you. for damage or consequential damage due to repairs or Best wishes, service work carried out by...
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 Maintenance work is divided up into Service, Inspection and Annual Inspection. BMW Inspection 1,000 km BMW Running-in Check after the first 1,000 km. BMW Service After the first 10,000 km and every further 20,000 km (30,000 km…, 50,000 km …, 70,000 km…)
Page 6: Confirmation Of Maintenance Work
Confirmation of maintenance work BMW Service, Pre-delivery Check 10,000 km Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions at odometer reading at odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection, BMW Inspection,...
Page 7 Confirmation of maintenance work BMW Service, BMW Service, 30,000 km 50,000 km Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions at odometer reading at odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection,...
Page 8 Confirmation of maintenance work BMW Service, BMW Service, 70,000 km 90,000 km Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions at odometer reading at odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection,...
Page 9 Confirmation of maintenance work BMW Service, BMW Service, 110,000 km 130,000 km Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions at odometer reading at odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection,...
Page 10 Confirmation of maintenance work BMW Service, BMW Service, 150,000 km 170,000 km Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions at odometer reading at odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection,...
Page 11 Carried out in accordance with Carried out 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 12 Carried out in accordance with Carried out 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 Confirmation of service work Record of all work carried out in workshop Work carried out 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 14 Confirmation of service work Record of all work carried out in workshop Work carried out 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 work Odometer replaced Odometer replaced Odometer reading is Odometer reading is not total distance covered not total distance covered at odometer reading at odometer reading Date, stamp, signature Date, stamp, signature Odometer replaced Odometer replaced Odometer reading is Odometer reading is not total distance covered not total distance covered...
Page 16 Confirmation of service work Odometer replaced Odometer replaced Odometer reading is Odometer reading is not total distance covered not total distance covered at odometer reading at odometer reading Date, stamp, signature Date, stamp, signature Odometer replaced Odometer replaced Odometer reading is Odometer reading is not total distance covered not total distance covered...
Page 17: General Instructions
Your motorcycle is equipped needed to keep your motorcy- with a digital engine manage- cle in optimum working order. ment system (MOTRONIC) and Your authorised BMW motorcy- a high-power ignition system. cle dealer possesses the nec- essary technical know-how and employs company-trained staff.
Page 18: Technical Modifications
General instructions Technical modifications are permitted only to a limited extent. Whenever you are planning BMW refuses to accept liability such modifications, comply for damage or consequential with all legal requirements. The damage due to repairs or motorcycle must not infringe...
Page 19 Toolkit Location The toolkit is stowed in the rear Note: seat When closing the stowage • Remove the front seat compartment, make sure that • Remove the rear seat and the grooves are aligned with the turn it upside down guides •...
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 Chapter 1 Kill switch activated Operate correctly Rider’s Manual, Chapter 3 Side stand extended Operate correctly Rider’s Manual, Chapter 3...
Page 21 – not described on pages mation is available in the follow- 15... 53 – attended to by a spe- ing publications: cialist workshop, preferably an – BMW Repair Manual authorised BMW motorcycle – BMW electrical circuit-dia- dealer. grams brochure...
Page 22: Removing The Front Wheel
• Raise the front wheel with forcing back the brake pads or front wheel stand, removing the calipers (mask off BMW special tool with tape if necessary). No. 36 3 970, or a suitable To prevent damage to the brake...
Page 23 Removing the front wheel Warning: Make sure that the motorcy- cle is standing firmly and cannot topple forward or to either side. • Remove securing screws 1 for the left and right brake calipers • Push the brake pads back a little by lightly rocking the Note: brake calipers...
Page 24 Removing the front wheel • Pull out quick-release axle 1 • Remove speedometer drive 4 and spacer bushing 5 • Roll the front wheel forwards and out Note: Attention: Mark the installed position on When setting down the front the tyre or ABS sensor ring wheel, avoid damage to the note the direction-of-rotation brake discs and ABS sensor...
Page 25: Installing The Front Wheel
• Roll the front wheel in when installing. between the fork legs Keep dirt and moisture away from the wheel bearings. Motorcycle with BMW Integral Attention: In order to avoid damaging the Do not damage the ABS sensor speedometer shaft, make sure...
Page 26 Installing the front wheel • Clean quick-release axle 1, grease it, and insert it from the right, turning it slightly at the same time (while holding the wheel up) • Hand-tighten axle screw 3 • Hand-tighten axle clamp screws 2 •...
Page 27 Warning: brake discs Motorcycle not equipped with • Install the brake calipers and BMW Integral ABS: when as- tighten screws 1 to the speci- sembly work has been com- fied tightening torque pleted, pull the handbrake...
Page 28: Removing The Rear Wheel
(mask off with tape if • Place the motorcycle on its necessary). centre stand on a flat, firm Motorcycle with BMW Integral surface ( Rider's Manual, : Do not damage the ABS Chapter 3) sensor cable, the ABS sensor •...
Page 29 Removing the rear wheel • Remove brake-caliper screws 2 for brake caliper 1 Attention: • Carefully push the brake pads Do not scratch the rim when back by lightly rocking the forcing back the brake pads or brake caliper removing the caliper (apply •...
Page 30 Removing the rear wheel • Motorcycle with BMW Integral ABS : note spacing washer 3 Attention: • Remove four wheel studs 1 Protect the wheel hub contact with taper rings 2 face against dust and dirt. • Lift the rear wheel clear of its...
Page 31: Installing The Rear Wheel
Attention: washer are free of grease Use only wheel studs with the • Motorcycle with BMW Integral same length code number. Do : slip spacing washer 3 not oil or grease the wheel onto wheel centering spigot studs.
Page 32 Installing the rear wheel Attention: Make sure that bracket A is correctly positioned. • Install front brake-caliper • Carefully slip brake caliper 1 screw 2 with bracket A over the brake disc • Tighten brake-caliper screws • Install rear brake-caliper 2, 3 to the specified tightening screw 3 with washer torque...
Page 33 Installing the rear wheel Warning: Tightening torque: Motorcycle not equipped with Preload torque BMW Integral ABS: when as- Wheel studs ....50 Nm sembly work has been com- Specified torque pleted, depress the footbrake Wheel studs ....105 Nm lever firmly several times to Brake caliper screws ..
Page 34: Checking Brake Pads
– If the wear indicating mark is authorised BMW motorcycle no longer clearly visible: dealer. Have the brake pads changed by a specialist • Make sure the ground is level...
Page 35: Rear Brake
For your safety, we recommend brake block: having work on the brake sys- Have the brake pads tem performed by a specialist changed by a specialist workshop, preferably an workshop, preferably an authorised BMW motorcycle authorised BMW motorcy- dealer. cle dealer.
Page 36: Notes On Changing Bulbs
Notes on changing bulbs Attention: Your vehicle has a high-beam/ low-beam bulb, a brake-light bulb/rear-light bulb, a parking- light bulb, a bulb for the Your motorcycle is equipped number-plate light, and four with a digital engine manage- bulbs for the turn indicators. ment system (MOTRONIC) and If any of these bulbs fail, you a high-power ignition system.
Page 37: Changing Bulbs
Attention: Switch off the ignition before changing a bulb. Note: • Make sure the ground is level Only motorcycle with BMW and firm and lift the motorcy- Integral ABS cle onto its centre stand The dimmed brake light takes • Remove securing screws 1 over the function of the rear •...
Page 38 Changing bulbs Low-beam/high-beam headlight • Carefully pull headlight insert 1 forward to remove Attention: • Disconnect multi-pin plug 4 Switch off the ignition before • Disconnect ground cable 6 changing a bulb. • Remove parking light 5 • Lay headlight insert 1 to one side Note: •...
Page 39: Parking Light
Changing bulbs Parking light • Carefully pull headlight Attention: insert 1 forward to remove Switch off the ignition before • Disconnect multi-pin plug 3 changing a bulb. • Disconnect ground cable 2 • Pull socket 4 down to remove it from the headlight insert Note: •...
Page 40 Changing bulbs • Place the motorcycle on its Turn indicator centre stand • Remove securing screw 1 • Remove the flashing turn indi- Attention: cator glass 3 Switch off the ignition before • Press bulb 2 into its socket, changing a bulb. and disengage it by turning it counter-clockwise.
Page 41: Replacing Fuses
Fuse assignments grips ......4 A 1 Instrument panel, 8 Low-beam headlight, instrument lighting number-plate light ..7.5 A indicator damping and 9 High-beam brake light (without headlight ....7.5 A BMW Integral ABS) ..4 A 10 Not used...
Page 42 It is advisable to have the elec- electrics unit by pressing the trical system checked by a spe- retainers in the direction indi- cialist workshop, preferably an cated by the arrow and authorised BMW motorcycle remove the cap dealer, if fuses blow frequently.
Page 43: Air Filter
Air filter Replacing the air filter element • Place the new filter element in • Make sure the ground is level position inside the air filter and firm and lift the motorcy- housing cle onto its centre stand • Installation is the reverse of •...
Page 44: Battery Safety Instructions
Battery safety instructions Gel batteries are maintenance- Warning: free. Compliance with the Do not attempt to jump-start instructions below is important the motorcycle using the on- in order to maximise battery life: board socket – Risk of fire! • Push-start the motorcycle Attention: only when the engine is –...
Page 45 In case of doubt ask a special- battery is not disconnected ist, preferably an authorised from the motorcycle's sys- BMW motorcycle dealer, to pre- tems, recharge it every pare the vehicle for laying up 2 months at the latest and to undertake the necessary –...
Page 46: Removing The Battery
Battery Removing the battery Warning: Take care not to damage fuel tank, wiring and hoses during • Place the motorcycle on its removal work. centre stand Disconnect the battery only • Remove the seat when the ignition is switched • Remove three screws 1 on off.
Page 47 Battery Note: In order to avoid damaging the paintwork, when working on the • Disconnect fuel-pump fuel tank lay a cloth between the cable 5 fork bridge and the tank. • Disconnect two breather Securing screw 8 for the fuel lines 6 at interface A tank is secured by a nut on the •...
Page 48 Battery • Release battery retaining strap 9 • Remove securing screw 1 • Disconnect the negative bat- from the intake air pipe tery lead 2. • Remove 2 screws 4 from the • Open the protective cap on air filter housing battery positive pole 3 •...
Page 49: Installing The Battery
Battery • Installation is the reverse of the removal procedure Installing the battery Note: Warning: Disconnecting the battery de- Before connecting the bat- letes all entries (e.g. faults, set- tery, switch off the ignition. tings) stored in the Motronic To avoid short-circuits: control unit's memory.
Page 50 Cleaning/care Attention: Do not use aggressive or pene- trating cleaning agents or sol- vents, as they would cause damage to rubber and plastic Note: parts. Regular cleaning, using the cor- Do not use a steam jet or high- rect methods, is an important pressure cleaning equipment.
Page 51: Washing The Motorcycle
• Clean/treat fairing elements the approved care products. only with cleaning and care products from the BMW Cleaning and Care Set Warning: • Do not use solvents or clean- After cleaning and before ing products to wash the...
Page 52 Cleaning/care Cleaning windscreen Removing road salt • Remove dirt and dead insects • Wash the motorcycle down with a soft sponge and plenty immediately with cold water at of water the end of the journey. Note: Note: Soften stubborn dirt or insects Do not use warm water –...
Page 53 Touching up paint damage • Minor damage caused by stones striking the painted Note: surface can be touched in Treat chrome-plated parts with a BMW paint pencil of the regularly with suitable care correct colour products. • Apply a wax-based corrosion- Attention:...
Page 54 BMW • Coat bright metal/chrome- motorcycle dealer. plated parts with an acid-free It is always a good idea to com- grease (e.g.
Page 55: Restoring To Use
Restoring to use • Run all safety checks Restoring to use Rider's Manual, • If necessary, remove protec- Chapter 2) tive wax coating • Check brakes • Clean the motorcycle ( Rider's Manual, Chapter 2) • Install a charged battery •...
Page 56 Engine Type Air-cooled, horizontally-opposed twin-cylinder engine with oil-cooled exhaust ports, one chain-driven camshaft per cylinder, 4 valves per cylinder, operated by bucket tap- pets and short pushrods, wet sump lubrication. Displacement 848 cc Max. output to DIN 70 020 54 kW at engine speed 7,000 rpm Max.
Page 57 Transmission Clutch Lightweight single-plate dry clutch mounted on crankshaft, with increased-leverage diaphragm spring and starter gear ring. Hydraulic actuation Clutch plate dia. 165 mm Gearbox 6-speed with claw shift and integral torsional vibration damper Gear ratios 1st gear = 3.863 2nd gear = 3.022 3rd gear = 2.393 4th gear = 1.961...
Page 58: Frame And Suspension
Sintered metal brake pads Note colour code ( Rear brake Hydraulically actuated disc brake with floating caliper and stainless steel disc. Semi-metal brake pads Brake system BMW Integral ABS partially integral Optional extra...
Page 59 Frame and suspension Wheel location front Quick-response wheel control (Telelever) with central spring strut rear Cast aluminium single swinging arm with reaction link to compen- sate for shaft drive effects (Paralever); with central spring strut. Steering lock angle 2 x 37° Front wheel castor in normal-load position 127 mm...
Page 60 Frame and suspension Front suspension Central spring strut with linear-rate coil spring (with taper-wound ends) and twin-tube, gas-filled shock absorber. Spring travel (bump) 60 mm Spring travel (rebound) 60 mm Total travel 120 mm Fork stanchion diameter 35 mm Rear suspension Central spring strut with coil spring and single-tube, gas-filled shock absorber.
Page 61 Frame and suspension Wheels and tyres BMW cast aluminium wheels with 5 double spoke design, low aspect ratio tyres Note: You can obtain detailed information on approved tyre sizes and makes from your authorised BMW motorcycle dealer or by visiting www.bmw-motorrad.com...
Page 62: Fuels And Lubricants
"Special Oils" are approved individually by BMW AG and availa- ble from your authorised BMW motorcycle dealer. 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 63 Fuels and lubricants Gear oil Brand-name hypoid gear oil, API class GL 5 Capacity Gearbox approx. 0.8 l (to bottom edge of filler neck) Rear-wheel drive approx. 0.25 l (disassembly) (to bottom edge of filler plug) Viscosity class EPX 90, alternatively SAE 90 API Type of fuel Super (premium) unleaded fuel to DIN 51 607 standard, minimum...
Page 64 –25 °C …+120 °C, drip point 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 Attention: Use only new brake fluid to DOT 4 specification.
Page 65: Electrical System
Electrical system Battery 12 V 19 Ah gel battery, maintenance-free Spark plugs Approved makes/types NGK BKR 7 EKC Electrode gap 0.8 mm Wear limit 1.0 mm Fuses "Minifuse" flat-socket fuses Amperage ratings 4 A, 7.5 A, 10 A, 15 A Headlight Round halogen headlight Bulbs...
Page 66: Dimensions And Weights
Dimensions and weights Overall length 2,170 mm Width across mirrors 870 mm across handlebars 850 mm (with handlebar weights) across front footrests 604 mm across rear footrests 734 mm Overall height 1,220 mm (without mirrors) Height of seat at unladen 780/800/820 mm, weight three-position adjustment...
Page 67: Performance Data
Performance data Top speed acc. to type approval test 200 km/h Flexibility 4th gear 80-120 km/h 4.22 s 5th gear 80-120 km/h 5.27 s 6th gear 80-120 km/h 8.39 s Power-to-weight ratio ready for road + rider (85 kg) 4.05 kg/kW at gross weight limit 7 kg/kW Ride-past noise level...
Page 68 Chrome, 51 Removing, 44 General instructions, 50 Technical data, 63 General notes, 48 Warranty, 42 Paint damage, 51 BMW Service, notes, 3 Removing road salt, 50 Bore/stroke, 54 Silencer, 51 Brake caliper, removal Washing, 49 Rear wheel, 27 Clutch, 55...
Page 69 E - P Electrical system, 63 Height of seat, 64 Engine oil Capacity, 60 Idle speed, 54 Consumption, 54 Inspection Technical data, 60 Notes, 3 Viscosity, 60 Engine, type, 54 Laying up the motorcycle, 52 Light bulbs, see Bulbs, 63 Flexibility, 65 Low-beam/high-beam Frame, 56...
Page 70 R - Z Toolkit, 17 Rear wheel Tools, 17 Installation, 29, 30, 31 Top speed, 65 Removal, 26, 27, 28 Torque, 54 Technical data, 59 Total weight, 64 Rear/brake light, 35 Touching up paint damage, 51 Rear-wheel drive Tread depth, 59 Technical data, 55 Troubleshooting, 18 Ride-past noise level, 65...
Page 74: Vehicle Data
Vehicle data Model Vehicle identification number Colour code First registration Registration number Dealership data Person to contact in Service Ms./Mr. Phone number Dealership address/phone (company stamp)
Page 75 No claims will be Errors and omissions excepted. entertained as a result of such dis- © 2004 BMW Motorrad crepancies. Not to be reproduced either wholly Dimensions, weights, fuel con- or in part without written permis-...
Page 76 BMW recommends Castrol BMW Motorrad Printed information Order No.: 01 41 7 693 281 05.2004 2nd edition GB / RF The Ultimate Driving Machine...

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