![BMW R850C (1999) [162/288] Assembling gearbox](/img/pdf.png)
BMW R850C (1999) [162/288] Assembling gearbox
![BMW R850C (1999) [162/288] Assembling gearbox](/views2/1121022/page162/bga2.png)
23.22
Assembling gearbox
Installing input, output and
intermediate shaft
•
Insert selector shaft (1) into intermediate shaft (2).
•
Align input, output and intermediate shafts so
that their gear teeth mesh and the selector fork is
in the position illustrated.
•
Push slip-over sleeve, BMW No. 23 4 712, on to
the input shaft splines.
L Note:
This is only necessary if the shaft sealing ring is in-
stalled.
•
Heat the bearing points on the cover to
80 … 100 °C (176 ... 212 °F).
•
Insert the input, output and intermediate shafts
together.
e Caution:
Check that the gearbox shafts are correctly seated.
•
Install the 1st/3rd gear and 2nd/4th gear selector
forks.
C230100
h
80…100
w
23 4 712
C230070
1
2
Содержание
- Repair manual 1
- Introduction 3
- Bmw ag motorcycle division maintenance schedule r 1100 s r 850 1200 c r 1150 gs 5
- Maintenance schedule 5
- Bmw ag motorcycle division pre delivery check r 1100 s r 850 1200 c r 1150 gs 6
- Pre delivery check 6
- Contents 7
- Changing engine oil renew oil filter element 9
- Changing oil in gearbox 9
- Changing oil in rear wheel drive cleaning inductive signal transmitter at rear wheel 9
- Checking battery acid level topping up if necessary cleaning greasing battery posts 9
- Checking brake fluid leve 9
- Checking throttle cable play adjusting if necessary 9
- Contents 9
- Key to maintenance intervals 9
- Maintenance and general instructions 9
- Reading out moditec fault memory 9
- Renewing fuel filter 9
- Renewing intake air cleaner element 9
- Renewing poly v belt 9
- Table of operating fluids 9
- Tightening torques 9
- Bleeding front brake circuit renewing brake flui 10
- Bleeding rear brake circuit renewing brake flui 10
- Check synchronising 10
- Checking adjusting valve operating clearances 10
- Checking brake disc wea 10
- Checking brake pads and discs for wear renewin 10
- Checking clutch operating fluid level 10
- Checking front brake pad wea 10
- Checking function of side prop stand contact switch 10
- Checking rear brake pad wea 10
- Checking rear wheel bearing play by tilting wheel 10
- Checking renewing spark plugs 10
- Checking swinging arm bearings adjusting if necessar 10
- Checking tightness of rear wheel studs 10
- Contents 10
- Final inspection with road safety and functional check 10
- Greasing the side prop stand pivot 10
- Renewing brake fluid and bleeding brake system 10
- Renewing brake pads front brak 10
- Renewing brake padsrear brak 10
- Tightening cylinder heads 10
- Tightening torques 11
- Table of operating fluids 17
- Checking throttle cable play adjusting if necessa 19
- Checking throttle cable play adjusting if necessary 19
- Inspections i and iii 19
- Inspections i ii iii and iv 19
- Key to maintenance intervals 19
- Reading out moditec fault memory 19
- Changing engine oil renew oil filter element 20
- Inspections i ii iii and iv 20
- Changing oil in gearbox 21
- Changing oil in rear wheel drive cleaning inducti 21
- Changing oil in rear wheel drive cleaning inductive signal transmitter at rear wheel 21
- Every 40 000 km 24 000 miles or at least every 2 21
- Inspections i iii and iv 21
- Inspections iii and iv 21
- Or at least every 2 years 21
- In normal operating conditions every 40 000 km 24 22
- Inspection iii 22
- Renewing fuel filter 22
- Checking battery acid level topping up if necessar 24
- Checking battery acid level topping up if necessary cleaning greasing battery posts 24
- In very dirty and dusty operating conditions rene 24
- Inspection iii 24
- Inspections iii and iv 24
- Renewing intake air cleaner element 24
- Every 60 000 km 36 000 miles 25
- Inspection iii 25
- Poly v belt adjusting procedure 25
- Renewing poly v belt 25
- Checking brake fluid level 26
- Checking brake system for correct operation and freedom from leaks repairing renewing if necessary 26
- Front brake 26
- Rear brake 26
- Checking brake disc wear 27
- Checking brake pads and discs for wear renewing 27
- Checking front brake pad wear 27
- Checking rear brake pad wear 27
- Inspections ii and iii 27
- Renewing brake pads front brake 28
- Renewing brake pads rear brake 28
- Abs inspection ii and iii 29
- Bleeding front brake circuit renewing brake fluid 29
- Inspection iv 29
- Renew the brake fluid annually 29
- Renewing brake fluid and bleeding brake system 29
- Additionally with abs 30
- Bleeding rear brake circuit renewing brake fluid 31
- Additionally with abs 32
- Checking clutch operating fluid level 32
- Inspections i ii and iii 32
- Checking function of side prop stand contact swi 33
- Checking function of side prop stand contact switch 33
- Checking rear wheel bearing play by tilting wheel 33
- Checking swinging arm bearings adjusting if neces 33
- Checking swinging arm bearings adjusting if necessary 33
- Checking tightness of rear wheel studs 33
- Greasing the side prop stand pivot 33
- Inspection i 33
- Inspection iii 33
- Inspections i and iii 33
- Inspections i ii and iii 33
- Inspections i ii iii and iv 33
- Checking adjusting valve operating clearances 34
- Inspection i 34
- Inspections i ii and iii 34
- Tightening cylinder heads 34
- Check synchronising 35
- Checking renewing spark plugs 35
- Inspection ii renewing inspection iii 35
- Inspections i ii and iii 35
- Final inspection with road safety and functional c 36
- Final inspection with road safety and functional check 36
- Inspections i ii iii and iv 36
- Road safety check 36
- Roadworthiness check 36
- Assembling piston 37
- Checking pistons and cylinder 37
- Contents 37
- Coolant circuit 37
- Dismantling checking repairing and re assembling cylinder hea 37
- Dismantling engine 37
- Dismantling reassembling valve gear holde 37
- Locking the engine in the tdc positio 37
- Lubricating oil circuit 37
- Removing and installing alternator cover with engine installe 37
- Removing and installing chain tensione 37
- Removing cylinder barre 37
- Removing cylinder hea 37
- Removing cylinder head cove 37
- Removing dismantling pisto 37
- Removing engine 37
- Removing installing conro 37
- Removing valve gear holde 37
- Sectioned drawing of engine 37
- Technical data 37
- Adjusting valve clearance 38
- Assembling engine 38
- Assembling engine bloc 38
- Checking conrod 38
- Contents 38
- Dismantling crankcas 38
- Installing auxiliary shaft driv 38
- Installing auxiliary shaft timing chain 38
- Installing clutch housin 38
- Installing conro 38
- Installing crankshaf 38
- Installing cylinde 38
- Installing cylinder hea 38
- Installing oil pum 38
- Installing pisto 38
- Installing the crankshaft radial sea 38
- Installing timing chain tensioning and slide rail 38
- Measuring big end bearing pla 38
- Measuring main and big end bearing pla 38
- Removing alternator mount cove 38
- Removing and installing oil pick up baske 38
- Removing auxiliary shaft driv 38
- Removing conrod 38
- Removing crankshaft auxiliary shaft and timing chain tensioning and slide rail 38
- Removing oil pum 38
- Removing radial shaft seal on crankshaft with engine installe 38
- Renewing radial shaft seal for rotary breathe 38
- Renewing radial shaft seal in alternator mount cove 38
- Replacing oil level sight glas 38
- Installing alternato 39
- Installing alternator mount cove 39
- Installing engine 39
- Installing left cylinder hea 39
- Installing magnetic gate belt pulle 39
- Installing right cylinder hea 39
- Sectioned drawing of engine 47
- Lubricating oil circuit 48
- Coolant circuit 49
- Removing engine 51
- Dismantling engine 54
- Removing cylinder head cover 55
- Locking the engine in the tdc position 56
- Top dead centre on ignition stroke 56
- Assembly specification for timing chain tensioner 57
- Removing and installing chain tensioner 57
- Removing valve gear holder 58
- Dismantling reassembling valve gear holder 59
- Removing cylinder head 61
- Rs110110 61
- Dismantling checking repairing and re assembling 62
- Dismantling checking repairing and re assembling cylinder head 62
- Removing and installing valves 62
- Removing valve stem seals 62
- Checking and repairing cylinder head 63
- Checking valve guide for wear 63
- Checking valves for wear 63
- Remachining valve seat 63
- Replacing valve guides 64
- Installing valve and valve stem seal 65
- Removing cylinder barrel 66
- Removing dismantling piston 66
- Assembling pistons 67
- Checking pistons and cylinders 67
- Removing installing conrod 68
- Removing alternator mount cover 69
- Removing and installing alternator cover with engi 69
- Removing and installing alternator cover with engine installed 69
- Renewing radial shaft seal for rotary breather 70
- Renewing radial shaft seal in alternator mount cov 70
- Renewing radial shaft seal in alternator mount cover 70
- Removing auxiliary shaft drive 71
- Removing oil pump 72
- Removing radial shaft seal on crankshaft with engi 73
- Removing radial shaft seal on crankshaft with engine installed 73
- Dismantling crankcase 74
- Remove screws on right side 74
- Rs110261 74
- Turn engine on to its side 74
- Remove screws on left side 75
- Remove upper section of crankcase 75
- Rs110260 75
- Turn engine on to its side 75
- Removing crankshaft auxiliary shaft and timing ch 76
- Checking conrods 77
- Removing and installing oil pick up basket 77
- Removing conrods 77
- Replacing oil level sight glass 77
- Measuring main and big end bearing play 78
- Measuring radial bearing play 78
- Installing main bearing 79
- Measuring axial bearing play 79
- Measuring big end bearing play 80
- Assembling engine 81
- Installing conrod 81
- Installing auxiliary shaft timing chains 82
- Installing crankshaft 82
- Installing timing chain tensioning and slide rails 82
- Assembling engine block 83
- Coat clean grease free sealing faces arrow with 3 bond 1209 83
- Secure the timing chain with rubber band 1 to the timing chain tensioning and slide rail 83
- Installing the crankshaft radial seal 85
- Installing clutch housing 86
- Installing oil pump 87
- Installing auxiliary shaft drive 88
- Installing piston 89
- Installing cylinder 90
- Installing cylinder head 91
- Adjusting valve clearances 92
- Adjustment specification 93
- Installing right cylinder head 93
- Adjustment specification 94
- Installing left cylinder head 94
- Installing alternator mount cover 96
- Installing magnetic gate belt pulley 96
- Timing the ignition 97
- Installing alternator 98
- Installing engine 99
- Check ignition coil resistanc 101
- Checking alternato 101
- Checking armature for short to ground earth 101
- Checking starter moto 101
- Checking starter rela 101
- Contents 101
- Dismantling reassembling alternator 101
- Dismantling reassembling starter motor 101
- Engine electrics 101
- Removing and installing alternator 101
- Removing and installing coil and ignition lead 101
- Removing and installing magnetic gate 101
- Removing and installing starter motor 101
- Renewing carbon brushe 101
- Technical data 101
- Timing the ignitio 101
- Check ignition coil resistance 105
- Removing and installing coil and ignition lead 105
- Poly v belt adjusting procedure 106
- Removing and installing alternator 106
- Checking alternator 107
- Checking armature for short to ground earth 107
- Dismantling reassembling alternator 107
- Removing and installing starter motor 108
- Checking starter motor 109
- Checking starter relay 109
- Dismantling reassembling starter motor 109
- Renewing carbon brushes 109
- Removing and installing magnetic gate 110
- Timing the ignition 111
- Contents 113
- Fuel preparation and control 113
- Removing and installing air cleaner 113
- Removing and installing injectors 113
- Removing and installing motronic control unit 113
- Removing and installing throttle positioner 113
- Removing and installing throttle potentiometer 113
- Removing and installing throttle stub pipe 113
- Technical data 113
- Removing and installing air cleaner 117
- Removing and installing throttle potentiometer 117
- Removing and installing throttle stub pipe 117
- Removing and installing injectors 118
- Removing and installing throttle positioner 118
- Removing and installing throttle potentiometer 118
- Removing and installing motronic control unit 119
- Contents 121
- Fuel tank and lines 121
- Removing and installing fuel distributor and pressure regulator 121
- Removing and installing fuel filte 121
- Removing and installing fuel filter fuel pump and fuel level sensor 121
- Removing and installing fuel pump and fuel level senso 121
- Removing and installing fuel tank 121
- Technical data 121
- Removing and installing fuel tank 125
- Removing and installing fuel filter 126
- Removing and installing fuel filter fuel pump and 126
- Removing and installing fuel filter fuel pump and fuel level sensor 126
- Checking fuel pump pressure 127
- Removing and installing fuel distributor and press 127
- Removing and installing fuel distributor and pressure regulator 127
- Removing and installing fuel pump and fuel level s 127
- Removing and installing fuel pump and fuel level sensor 127
- Contents 129
- Exhaust system 129
- Removing and installing exhaust system 129
- Removing and installing front exhaust pipe 129
- Removing and installing silencer muffler 129
- Removing and installing exhaust system 131
- Removing and installing front exhaust pipes 131
- Removing and installing silencer muffler 131
- Clutch 133
- Contents 133
- Filling bleeding clutch line 133
- Installing clutc 133
- Removing and installing clutch 133
- Removing and installing clutch hydraulic line 133
- Removing and installing clutch slave cylinder 133
- Removing clutc 133
- Technical data 133
- Installing clutch 137
- Removing and installing clutch 137
- Removing clutch 137
- Removing and installing clutch hydraulic line 138
- Removing and installing clutch slave cylinder 138
- Filling bleeding clutch line 139
- Assembling gearbox 141
- Assembling gearbox housin 141
- Checking adjusting fully compressed length of gearbox shafts selector dru 141
- Checking endpla 141
- Contents 141
- Dismantling assembling input shaf 141
- Dismantling assembling selector shaf 141
- Dismantling gearbox 141
- Dismantling reassembling output shaf 141
- Gearbox 141
- Installing input output and intermediate shaf 141
- Installing selector dru 141
- Installing selector shaf 141
- Removing and installing gear pedal 141
- Removing gearbox 141
- Removing gearbox housin 141
- Removing gearbox shaft 141
- Removing selector dru 141
- Renewing deep groove ball bearing on intermediate shaf 141
- Renewing the shaft sealing rings in the gearbox housing and gearbox cove 141
- Shimming selector shaf 141
- Technical data 141
- 8 581 00 8 582 145
- Removing and installing gear pedal 145
- Removing gearbox 145
- Renew the input shaft sealing ring at the input en 147
- Renewing output shaft sealing ring 147
- Renewing the shaft sealing rings in the gearbox ho 147
- Renewing the shaft sealing rings in the gearbox housing and gearbox cover 147
- 4 721 23 4 722 148
- Renewing input shaft sealing ring at output side 148
- Renewing sealing ring for selector shaft 148
- Renewing shaft sealing ring for selector drum 148
- Dismantling gearbox 149
- Removing gearbox housing 149
- Dismantling assembling selector shaft 150
- Removing selector drum 150
- Removing gearbox shafts 151
- Renewing deep groove ball bearing on intermediate 151
- Renewing deep groove ball bearing on intermediate shaft 151
- Dismantling assembling input shaft 152
- Dismantling input shaft 152
- Assembling input shaft 153
- Dismantling reassembling output shaft 154
- Stripping down output shaft 154
- 18 16 15 155
- Assembling output shaft 155
- Nd gear 155
- Rd gear 155
- St gear 155
- Th gear 155
- Checking endplay 156
- Checking adjusting fully compressed length of gear 157
- Checking adjusting fully compressed length of gearbox shafts and selector drum 157
- Checking adjusting fully compressed length of inte 157
- Checking adjusting fully compressed length of outp 158
- Checking adjusting fully compressed length of inpu 159
- Checking adjusting fully compressed length of sele 160
- Shimming selector shaft 161
- Assembling gearbox 162
- Installing input output and intermediate shaft 162
- Installing selector drum 163
- Installing selector shaft 163
- Assembling gearbox housing 164
- Assembling telescopic for 167
- Checking friction at ball joint ball thrust bearin 167
- Contents 167
- Dismantling reassembling leading link 167
- Dismantling reassembling telescopic fork 167
- Dismantling telescopic for 167
- Front fork 167
- Measuring telescopic fork 167
- Removing and installing front suspension strut 167
- Removing and installing leading link 167
- Removing and installing slider tube bridg 167
- Removing and installing telescopic for 167
- Removing and installing telescopic fork 167
- Technical data 167
- Removing and installing fork bridge 171
- Removing and installing telescopic fork 171
- Removing and installing pot type joints 172
- Removing and installing ball thrust bearing 173
- Checking friction at ball joint ball thrust bearin 174
- Checking friction at ball joint ball thrust bearing 174
- Removing and installing ball joint 174
- Removing and installing slider tube bridge 174
- Assembly specification for telescopic fork 175
- Assembling telescopic fork 176
- Dismantling reassembling telescopic fork 176
- Dismantling telescopic fork 176
- Check slider tube bridge 177
- Checking runout of fixed tube 177
- Measuring telescopic fork 177
- Dismantling reassembling leading link 178
- Removing and installing front suspension strut 178
- Removing and installing leading link 178
- Contents 179
- Removing and installing handlebar 179
- Removing and installing left handlebar fitting 179
- Removing and installing right handlebar fitting 179
- Removing installing throttle cable 179
- Steering 179
- Technical data 179
- Removing and installing left handlebar fitting 183
- Removing and installing right handlebar fitting 184
- Removing and installing handlebar 185
- Removing installing throttle cable 186
- Assembling input bevel pinio 187
- Assembling installing crown whee 187
- Checking adjusting backlas 187
- Checking tooth contact patter 187
- Contents 187
- Disassembling input bevel pinio 187
- Installing drive shaf 187
- Installing housing cove 187
- Installing input bevel pinio 187
- Installing rear swinging ar 187
- Installing rear wheel driv 187
- Installing splined elemen 187
- Rear wheel drive 187
- Removing and dismantling the crown whee 187
- Removing and installing flexible gaite 187
- Removing and installing suspension strut 187
- Removing and installing taper roller bearin 187
- Removing dismantling reassembling and installing rear wheel drive 187
- Removing drive shaf 187
- Removing input bevel pinio 187
- Removing installing rear swinging fork 187
- Removing rear swinging ar 187
- Removing rear wheel driv 187
- Shimming housing cove 187
- Technical data 187
- Removing dismantling reassembling and installing 191
- Removing dismantling reassembling and installing rear wheel drive 191
- Removing input bevel pinion 191
- Removing rear wheel drive 191
- Disassembling input bevel pinion 193
- Installing needle roller bearing for input bevel p 193
- Removing needle roller bearing for input bevel pin 193
- Assembling input bevel pinion 194
- Installing input bevel pinion 195
- Removing and dismantling the crown wheel 196
- Assembling installing crown wheel 197
- Checking adjusting backlash 198
- Checking tooth contact pattern 199
- Installing housing cover 200
- Installing splined element 200
- Shimming housing cover 200
- Removing installing rear swinging fork 201
- Removing rear swinging arm 201
- Checking universal joint for wear 202
- Installing drive shaft 202
- Removing and installing flexible gaiter 202
- Removing and installing taper roller bearing 202
- Removing drive shaft 202
- Installing rear swinging arm 203
- Installing rear wheel drive 204
- Removing and installing suspension strut 205
- Adjusting front abs sensor gap 207
- Adjusting rear abs sensor gap 207
- Assembling front brake calipe 207
- Assembling rear brake calipe 207
- Brakes 207
- Checking and adjusting reliefclearance of piston ro 207
- Checking and adjusting sensor ga 207
- Contents 207
- Dismantling and assembling front brake caliper 207
- Dismantling and assembling rear brake caliper 207
- Dismantling front brake calipe 207
- Dismantling rear brake calipe 207
- Marking sensor whee 207
- Removing and installing abs unit 207
- Removing and installing brake pedal 207
- Removing and installing front abs sensor 207
- Removing and installing front brake caliper 207
- Removing and installing front brake disc 207
- Removing and installing rear abs sensor 207
- Removing and installing rear brake caliper 207
- Removing and installing rear brake master cylinder 207
- Removing installing rear brake disc 207
- Technical data 207
- Contents 208
- Installing the abs rela 208
- Installing the abs relay bas 208
- Installing the abs uni 208
- Removing abs rela 208
- Removing abs relay bas 208
- Removing and installing abs relay and relay base 208
- Removing and installing brake lines 208
- Removing and installing front brake lin 208
- Removing and installing rear brake lin 208
- Removing the abs uni 208
- Removing and installing front brake caliper 211
- Assembling front brake caliper 212
- Dismantling and assembling front brake caliper 212
- Dismantling front brake caliper 212
- Removing and installing rear brake caliper 213
- Assembling rear brake caliper 214
- Dismantling and assembling rear brake caliper 214
- Dismantling rear brake caliper 214
- Removing and installing front brake disc 215
- Removing installing rear brake disc 216
- Removing and installing front abs sensor 217
- Adjusting front abs sensor gap 218
- Checking and adjusting sensor gap 218
- Marking sensor wheel 218
- Removing and installing rear abs sensor 219
- Adjusting rear abs sensor gap 220
- Checking and adjusting sensor gap 220
- Marking sensor wheel 220
- Checking and adjusting relief clearance of piston 221
- Checking and adjusting relief clearance of piston rod 221
- Removing and installing brake pedal 221
- Removing and installing rear brake master cylinder 221
- Removing and installing abs unit 222
- Removing the abs unit 222
- Installing the abs unit 223
- Installing the abs relay 224
- Removing abs relay 224
- Removing abs relay base 224
- Removing and installing abs relay and relay base 224
- Installing the abs relay base 225
- Removing and installing brake lines 226
- Removing and installing front brake line 226
- Removing and installing rear brake line 227
- Centering lateral runou 229
- Centering the wheel rim 229
- Checking front rear wheel rim for runout 229
- Contents 229
- Installing front whee 229
- Removing and installing front wheel 229
- Removing and installing wheel bearing 229
- Removing front whee 229
- Removing installing rear wheel 229
- Removing installing spokes 229
- Static balancing of front wheel rear wheel 229
- Technical data 229
- Wheels and tyres 229
- Installing front wheel 233
- Removing and installing front wheel 233
- Removing front wheel 233
- Removing and installing wheel bearings 234
- 5 512 3 235
- Removing installing rear wheel 236
- Static balancing of front wheel rear wheel 237
- Checking front rear wheel rim for runout 238
- Centering lateral runout 239
- Centering the wheel rim 239
- Removing installing spokes 239
- Checking running gear 241
- Contents 241
- Measuring wheel track offse 241
- Removing and installing front frame 241
- Removing and installing rear frame 241
- Removing and installing rear mudguard 241
- Removing and installing side prop stand 241
- Removing installing footrest supports 241
- Removing installing front mudguard 241
- Technical data 241
- Removing and installing rear mudguard 245
- Removing installing front mudguard 245
- Removing and installing front frame 246
- Removing and installing rear frame 248
- Removing and installing side prop stand 250
- Removing installing footrest supports 250
- Checking running gear 251
- Measuring wheel track offset 251
- Contents 253
- Equipment 253
- Removing and installing ignition light switc 253
- Removing and installing ignition switch steering lock 253
- Removing and installing lock barre 253
- Removing and installing lock barrel for fuel tank filler cap 253
- Drilling out lock barrel 255
- Removing and installing ignition light switch 255
- Removing and installing ignition switch steering l 255
- Removing and installing ignition switch steering lock 255
- Removing and installing lock barrel 255
- Drilling out lock barrel 256
- Removing and installing lock barrel for fuel tank 256
- Removing and installing lock barrel for fuel tank filler cap 256
- Contents 257
- Removing and installing seat 257
- Removing and installing seat 259
- Contents 261
- Frame wiring harness 261
- General electrical equipment 261
- Relay positions central electrical equipment box 261
- Removing and installing central electrical equipment box 261
- Technical data 261
- Wiring harness view from lef 261
- Wiring harness view from righ 261
- Removing and installing central electrical equipme 265
- Removing and installing central electrical equipment box 265
- 6 4 5 7 8 9 10 266
- Connections to fuses 266
- Relay positions central electrical equipment box 266
- Frame wiring harness 267
- Wiring harness view from left 268
- Wiring harness view from right 272
- Contents 277
- Dismantling and assembling instrument cluster 277
- Instruments 277
- Removing and installing instrument cluster 277
- Technical data 277
- Dismantling and assembling instrument cluster 281
- Removing and installing instrument cluster 281
- Adjusting headligh 283
- Contents 283
- Lights 283
- Removing and installing headlight 283
- Technical data 283
- Adjusting headlight 287
- Removing and installing headlight 287
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