BMW Motorrad R 850 R 2004 Maintenance Instruction

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Maintenance Instructions

R 1150 R

R 850 R

BMW Motorrad

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Page 1 Maintenance Instructions R 1150 R R 850 R 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...
Page 2 Please note Warning: This symbol stands for precau- tions and measures which are essential in order to protect the rider or other persons from pos- sibly severe or fatal injury. Caution: 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 ser- Best wishes vice work carried out by other than BMW-authorised work- BMW Motorrad shops.
Page 4: Important Safety Information
Important safety information Note however that BMW is unable to accept liability for spare parts and accessories which it has not approved. 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.
Page 5: Maintenance Work
Maintenance work Maintenance work is divided up into Service, Inspection and Annual Service. 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 miles …, 70,000 miles…) BMW Inspection Note:...
Page 6: Confirmation Of Maintenance Work
Confirmation of maintenance work BMW Pre-delivery BMW Service check 10,000 km Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection BMW Inspection 1,000 km 20,000 km Carried out in accordance with Carried out in accordance with...
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 Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection BMW Inspection 40,000 km 60,000 km Carried out in accordance with...
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 Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection BMW Inspection 80,000 km 100,000 km Carried out in accordance with...
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 Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection BMW Inspection 120,000 km 140,000 km Carried out in accordance with...
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 Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection BMW Inspection 160,000 km 180,000 km Carried out in accordance with...
Page 11: Bmw Annual Service
Confirmation of maintenance work BMW Annual Service BMW Annual Service 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 Confirmation of maintenance work BMW Annual Service BMW Annual Service 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 Confirmations of service work Record of all work carried out in workshop Work details Odometer reading Date The list is intended as a record of maintenance, warranty and repair work, the installation of accessories and, if appropriate, special campaign work.
Page 14 Confirmations of service work Record of all work carried out in workshop Work details Odometer reading Date The list is intended as a record of maintenance, warranty and repair work, the installation of accessories and, if appropriate, special campaign work.
Page 15 Confirmations of service work Record of all work carried out in workshop Work details Odometer reading Date The list is intended as a record of maintenance, warranty and repair work, the installation of accessories and, if appropriate, special campaign work.
Page 16 Confirmations of service work Odometer renewed Odometer renewed 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 renewed Odometer renewed 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 Electronics (MOTRONIC) and an increased- output ignition system. If you intend to perform the maintenance and general care Warning: 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 not touch electrically live...
Page 18 General instructions Remember: the safety and reli- ability of your motorcycle are the most important considera- tions. You should therefore not attempt any complex repair or maintenance tasks. Your authorised BMW motor- Keep to the specified Inspec- cycle dealer possesses the tion and Service intervals.
Page 19 BMW Motorrad refuses to Note: accept any liability whatsoever Manipulation of the MOTRONIC for other-make spare parts and control unit voids the warranty.
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 is Operate correctly Rider’s Manual extended Power supply Blown fuse...
Page 21 Troubleshooting chart Note: Note: It is advisable to have other More detailed technical infor- faults – not described on pages mation is available in the follow- 15...57 – attended to by a spe- ing publications: cialist workshop, preferably an – BMW Repair Manual authorised BMW motorcycle –...
Page 22: Removing The Front Wheel
Removing the front wheel Caution: • On a smooth, firm surface, When removing, avoid damage place the motorcycle on its to brake pipes, brake discs, main (centre) stand (Rider's brake pads or the wheel rim Manual Chapter 2). (mask off with tape if neces- •...
Page 23 Removing the front wheel • Remove the securing screws 1 for the left and right brake calipers Caution: • Tilt the brake calipers to force Do not scratch the rim when back the brake pads forcing back the brake pads or •...
Page 24 Removing the front wheel • Remove speedometer drive 4 and spacing bushing 3 • Roll the front wheel out for- wards • Remove axle bolt 5 Caution: • Slacken off axle clamp When setting down the front screws 1 at left and right wheel, avoid damage to the •...
Page 25: Installing The Front Wheel
Installing the front wheel • Roll the front wheel in between the fork stanchions Caution: Caution: Avoid damage to brake lines, To avoid damaging the speed- discs and pads when installing. ometer drive, make sure that Keep dirt and moisture away lug A on the sliding tube engag- from the wheel bearings.
Page 26 Installing the front wheel Warning: Make sure that the motor- cycle is standing firmly and cannot tip forwards or to either side • Tighten axle bolt 3 to the cor- rect torque • Clean the quick-release • Tighten axle clamp screws 1 axle 2, grease it and insert it at left and right to the speci- from the right, turning slightly...
Page 27 Installing the front wheel Warning: Motorcycle not equipped with BMW Integral ABS: when as- sembly work has been com- pleted, pull the brake lever Caution: firmly several times to check Always have the tightening tor- that the front brake is operat- ques checked by a specialist ing correctly.
Page 28: Removing The Rear Wheel
Removing the rear wheel Warning: Make sure that the motorcycle is standing firmly and cannot topple forwards or to either side. Caution: • On a smooth, firm surface, When removing, avoid damage place the motorcycle on its to brake pipes, brake discs, main (centre) stand (Rider's brake pads or the wheel rim Manual...
Page 29 Removing the rear wheel • Remove screws 2 securing Caution: brake caliper 1 Do not scratch the wheel when • Force back the brake pads by forcing back the brake pads or tilting the caliper carefully removing the caliper (apply •...
Page 30 Removing the rear wheel • Important for BMW Integral note spacing washer 3 Caution: • 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 centering spigot, tilt it and take it out downwards Optional extra...
Page 31: Installing The Rear Wheel
Installing the rear wheel • Check that the wheel center- ing spigot and the contact faces on the wheel hub and spacing washer are free from grease • Important for BMW Integral Caution: , push spacing washer Use only wheel studs with the 3 on to the wheel centering same length code number.
Page 32 Installing the rear wheel • Install front brake-caliper screw 2 with retaining angle A • Carefully place brake caliper 1 • Tighten brake-caliper over the brake disc screws 2, 3 to specified torque Caution: Make sure that retaining Tightening torque: angle A is in the correct posi- Preload torque tion.
Page 33 Installing the rear wheel Warning: Motorcycle not equipped with BMW Integral ABS: when as- sembly work has been com- pleted, depress the brake pedal firmly several times to check that the rear brake is operating correctly. Caution: BMW Integral ABS : once Always have the tightening assembly work on the brake...
Page 34: Checking Brake Pads
Checking brake pads Front brake Caution: Have brake pads replaced be- • Visually inspect to ensure that fore the minimum permitted both brake pads and the thickness is reached. brake caliper bear have the same colour-code marks 2 • Make a visual check on brake Note: pad thickness For your safety, we recommend...
Page 35: Rear Brake
Checking brake pads • Make sure the ground is level Rear brake and firm and lift the motor- cycle onto its main stand • Visually check brake pad Caution: thickness Have brake pads replaced be- – Minimum pad thickness: fore the minimum permitted Make sure that the brake thickness is reached.
Page 36: Notes On Changing Bulbs
Notes on changing bulbs Caution: Your vehicle has a high-beam/ low-beam bulb, a brake-light bulb/rear-light bulb, a parking- Your motorcycle is equipped light bulb, a bulb for the with Digital Motor Electronic number-plate light, and four (MOTRONIC) engine manage- bulbs for the turn indicators. ment and a high-power ignition If any of these bulbs fail, you system.
Page 37: Changing Bulbs
Changing bulbs Note: Motorcycle with BMW Integral only: The dimmed brake light takes over the function of the rear light should the rear light fail. A warning lamp 1 lit in the cockpit indicates that this is the case. Rider’s Manual, Chapter 3). Rear/brake light Do not touch the glass of new bulbs with your fingers.
Page 38 Changing bulbs • Turn bulb socket 2 counter- clockwise to disengage and remove it from the rear light • Press bulb 4 into its socket • Place the motorcycle on its and turn it counter-clockwise main stand on a firm, flat sur- to release face •...
Page 39 Changing bulbs Number-plate light Caution: Switch off the ignition before changing a bulb. Note: • Place the motorcycle on its Do not touch the glass of new main stand bulbs with the fingers. Use a • Remove 2 retaining screws 2 clean, dry cloth to hold the •...
Page 40 Changing bulbs • Pull off cap 3 • Press bulb 4 into its socket and turn it counter-clockwise Note: to release When installing the bulb, make • Remove the bulb sure the pins on the base are • Installation is the reverse of correctly aligned with the the removal procedure recesses 5 in the socket.
Page 41 Changing bulbs Low/high headlight beam • Carefully pull headlight unit 1 Caution: forwards and remove it Switch off the ignition before • Pull off multi-pin plug 4 changing a bulb. • Disconnect ground cable 6 • Remove parking light 5 •...
Page 42: Parking Light
Changing bulbs • Place the motorcycle on its main stand • Remove retaining screw 6 • Carefully pull headlight unit 1 Parking light forwards and remove it • Pull off multi-pin plug 3 • Disconnect ground cable 2 Caution: • Pull bulb holder 4 out of the Switch off the ignition before headlight unit downwards changing a bulb.
Page 43 Changing bulbs • Place the motorcycle on its Flashing turn indicator main stand • Take out retaining screw 1 • Take off the flashing turn indi- Caution: cator glass 3 Switch off the ignition before • Press bulb 2 into its socket changing a bulb.
Page 44: Replacing Fuses
Replacing fuses 2 Parking lights, tail light Caution: (without BMW Integral Before changing a fuse, switch ABS), ABS ....4 A off the ignition. 3 Clock, 12 V socket, Never attempt to repair a blown speedometer ....15 A fuse – risk of fire! 4 Horn ......
Page 45 Replacing fuses Replacing fuses • Place the motorcycle on its main stand • Remove the dualseat • Close the lid of the central • Press the tabs in the direction electrical equipment box indicated by the arrow to • Close and lock the seat release, and remove the cover of the central electrical equipment box...
Page 46: Air Filter
Air filter • Remove screw 3 and remove cover 4 from the fuel lines. Replacing air filter • Remove front securing element screws 5 of the left and right side panels, complete with washers. Note: • Remove securing screw 1 To avoid damaging the paint- from the fuel tank work when working on the fuel...
Page 47 Air filter • Remove two securing screws 1 from air filter cover 5 • Raise air filter cover 5 at the front and remove it from the air filter housing • Remove old filter element 4 from the air filter housing Note: •...
Page 48: Battery Safety Instructions
Battery safety instructions Warning: Gel batteries are maintenance- Do not attempt to jump-start free. Compliance with the the motorcycle using the on- instructions below is important board socket in order to maximise battery life: – Risk of fire! • Push-start the motorcycle only when the engine is Caution: cold.
Page 49 Battery safety instructions – Batteries that are not in use must be stored in a cool place. Do not store a Motorcycle out of use for a discharged battery lengthy period – If the battery is in storage for • The battery has to be charged an extended period of time, prior to lay-up periods of recharge it at regular intervals...
Page 50: Removing The Battery
Battery Removing the battery • Place the motorcycle on its Warning: main stand Avoid damage to fuel tank, • Remove the dualseat wiring and hoses during • Remove screw 2 and remove removal work. cover 3 from the fuel lines Before disconnecting the bat- •...
Page 51 Battery Note: To avoid damaging the paint- work when working on the fuel tank, lay a cloth between the fork bridge and the fuel tank. • Disconnect two breather • Remove 3 screws 6 on each lines 9 side and remove the oil cool- •...
Page 52 Battery • Remove diagnosis connector 6 from its holder • Disconnect plug 7 of the air- temperature sensor • Remove retaining screw 1 for • Disconnect the battery nega- air intake pipe tive cable 2 • Remove 2 screws 4 from the •...
Page 53: Installing The Battery
Battery • Installation is the reverse of Installing the battery the removal procedure Warning: Note: Before connecting the bat- Disconnecting the battery de- tery, switch off the ignition. letes all entries (e.g. faults, set- To avoid short-circuits: tings) stored in the Motronic •...
Page 54 Cleaning/care Caution: Avoid damage to rubber or plastic parts caused by aggres- sive or penetrating cleaning Note: agents or solvents. Regular cleaning, using the cor- Do not use a steam jet or high- rect methods, is an important pressure cleaning equipment. factor in maintaining the value High water pressure can dam- of your motorcycle.
Page 55: Washing The Motorcycle
Cleaning/care Washing the motorcycle • Make sure the ground is level and firm and lift the motor- • Remove tar splashes only cycle onto its main stand with an approved cleansing • Clean the wheels, engine, agent – rinse the affected area gearbox and swinging arm thoroughly.
Page 56 Cleaning/care Cleaning the 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 57 Cleaning/care Care of chromed parts Touching up damage • Minor damage caused by stones striking the painted Note: surface can be touched up Treat chromed parts regularly with a BMW touch-up pencil with suitable care products. of the correct colour •...
Page 58 Laying up Laying up • Clean the motorcycle 52-55) • Remove the battery Note: 48-50) Before laying the vehicle up out • Spray the clutch lever pivots of use have the engine oil and and the main and side stand the oil filter element changed by pivots with a suitable lubri- a specialist workshop, prefera-...
Page 59: Restoring To Use
Restoring to use Restoring to use • Perform safety checks • If necessary, remove protec- (Rider's Manual 19-43) tive wax coating • Check the brakes • Clean the motorcycle ( (Rider's Manual 26-33) • Install a charged battery • Check/correct tyre pressures (Rider's Manual...
Page 60 Engine R 1150 R R 850 R Type Air-cooled flat-twin (“Boxer”) with additional oil cooling in the exhaust valve areas and a single side- mounted, chain-driven camshaft on each side, operating 4 valves per cyl- inder by means of tappets and short pushrods;...
Page 61 Transmission R 1150 R R 850 R Clutch Lightweight single-plate dry clutch mounted on crankshaft, with increased-leverage diaphragm spring and starter gear ring. Hydraulic actuation Clutch plate Ø 165 mm Gearbox 6-speed with claw shift and integral torsional vibration damper Gear ratios gear = 3.863 gear = 3.022...
Page 62: Frame And Suspension
Frame and suspension R 1150 R R 850 R Frame Three-part frame. A cast aluminium front frame connects the load-bear- ing engine and gearbox assembly to the tubular steel rear frame. A forged aluminium footrest plate increases the strength of the gearbox mount.
Page 63 Frame and suspension R 1150 R R 850 R Wheel location Front Light-touch wheel guidance (Telelever) with central suspen- sion strut. Rear Cast aluminium single swinging arm with additional torque reac- tion strut to compensate for shaft drive effects (Paralever); central suspension strut.
Page 64 Frame and suspension R 1150 R R 850 R Rear suspension Central strut with coil spring and single-tube gas-filled shock absorber. Hydraulic spring preload adjustment. Continuously variable rebound damping setting. Spring compression 90 mm Spring extension 45 mm Total travel (at wheel) 135 mm Swinging arm length 506 mm...
Page 65 Frame and suspension R 1150 R R 850 R Wheels and tyres BMW cast-aluminium wheels with 5 double-spoke design, low aspect-ratio tyres Front wheel Angled rim shoulder and double tyre retaining hump Size and designation 3.50 x 17 MT H2 Tyre size and designation 120/70 ZR17 TUBELESS Rear wheel...
Page 66: Fluids And Lubricants
Temperatures above or below the limits quoted for the individ- ual SAE classifications are permitted for brief periods only. Special Oils are approved individually by BMW Motorrad and available from your authorised BMW motorcycle dealer. All engine oils supplied by BMW are subjected to regular BMW quality assurance checks.
Page 67 Fluids and lubricants R 1150 R R 850 R Gearbox oil Brand-name hypoid gear oil, API class GL 5 Quantity Gearbox approx. 0.80 l (to bottom edge of filler opening) Final drive approx. 0.25 l (to bottom edge of filler opening) Viscosity class EPX 90 alternatively SAE 90 API Fuel grade...
Page 68 Fluids and lubricants R 1150 R R 850 R Bearings and other Brand-name anti-friction bearing lubrication points grease, usable temperature range –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...
Page 69: Electrical System
Electrical system R 1150 R R 850 R Battery Gel battery, 12 V 19 Ah maintenance-free Spark plugs Approved makes/types NGK BKR 7 EKC Primary spark plug Bosch YR6LDE or Secondary spark plug NGK DCPR 8 EKC Electrode gap 0.8 mm Wear limit 1.0 mm Fuses...
Page 70: Dimensions And Weights
Dimensions and weights R 1150 R Overall length 2,170 mm Width across mirrors 940 mm across handlebars (with 820 mm handlebar weights) across front footrests 604 mm across rear footrests 734 mm Overall height 1,220 mm (excl. mirrors) Seat height, unladen 800 mm Wheelbase - in normal-load position...
Page 71: Performance Data
Performance data R 1150 R R 850 R Top speed acc. to type approval test 197 km/h 187 km/h Flexibility 4th gear 80-120 km/h 3.38 s 4.32 s 5th gear 80-120 km/h 4.10 s 5.65 s 6th gear 80-120 km/h 4.86 s 7.20 s 4th gear 60-140 km/h...
Page 72 A - E Accessories, genuine BMW Capacities Parts, 17 engine oil, 64 Accessories, genuine BMW gearbox, 65 parts, 17 Care products, 55 Air filter, 44 Castor, 61 Annual Service, instructions, 3 Chromed parts care of, 55 Cleaning/care, 53 Battery chrome, 55 charging, 46 general instructions, 52, 54 installing, 51...
Page 73 F - P Flashing turn indicator, 41 Laying up, 56 Flexibility, 69 Light bulbs, see bulbs, 67 Frame, 60 Low/high headlight beam, 39 Frame number, 60 Front wheel Maintenance work, confirmation installing, 23, 25 of, 4 removing, 20, 22 Motorcycle technical data, 63 laying up out of use, 56 Front wheel stand, 20...
Page 74 R - Z Top speed, 69 Rear wheel Torque, 58 installing, 29, 30, 31 Troubleshooting, 18 removing, 26, 27, 28 Type plate, 60 technical data, 63 Tyre tread depth, 63 Rear wheel drive Tyres, 63 technical data, 59 approved tyre sizes, 63 Rear/brake light, 35 pressures, 63 technical data, 63...
Page 78 Motorcycle data Model Frame No. Colour No. First registered on Registration No. Dealer data Person to contact for Service work Ms./Mr. Tel. No. Dealer’s address with telephone No. (company stamp)
Page 79 No claims will be Errors and omissions excepted. entertained as a result of such © 2004 BMW Motorrad discrepancies. Not to be reproduced either wholly Dimensions, weights, fuel con- or in part without written permis-...
Page 80 BMW recommends Castrol BMW Motorrad Printed information Order No.: 01 41 7 693 261 05.2004 The Ultimate 4th edition GB / RF Driving Machine...

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