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BMW R1200C Motorcycle 2002-2003 Service Repair Workshop Manual
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Basic Information Identification Make: BMW Model: R1200C Model Nickname: R 1200 C Cruiser Year: 2002-2003 Codes Chassis Code Range: 0350 Introduction Market Position Segment: Cruiser Motorcycle Target Audience: BMW R1200C...
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| Basic Information | |
| Identification | |
| Make: | BMW |
| Model: | R1200C |
| Model Nickname: | R 1200 C Cruiser |
| Year: | 2002-2003 |
| Codes | |
| Chassis Code Range: | 0350 |
| Introduction | |
| Market Position | |
| Segment: | Cruiser Motorcycle |
| Target Audience: | BMW R1200C owners, independent repair shops, motorcycle enthusiasts seeking in-depth technical knowledge. |
| Competitive Analysis | |
| Key Competitors: | Harley-Davidson models, Honda Shadow series, Kawasaki Vulcan series, Yamaha V-Star series. |
| Key Features | |
| Design Philosophy: | Fusion of BMW's engineering prowess with classic American cruiser aesthetics, featuring the iconic Boxer engine in a custom-style package. |
| Unique Selling Points: | Telelever front suspension (on some variants, though R1200C often had conventional telescopic), shaft drive, distinct styling, boxer engine character. |
| Manual Details | |
| Coverage Areas | |
| Primary Coverage: | BMW R1200C Motorcycle |
| Specific Years Covered: | 2002, 2003 |
| Page Count | |
| Estimated Pages: | 300-500 (typical for this era and model scope) |
| Manual Type | |
| Type: | Factory Service Repair Workshop Manual |
| Language | |
| Language: | English (standard for BMW factory manuals) |
| Format | |
| Format: | Downloadable PDF |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Full coverage: disassembly, assembly, torque specifications, valve adjustment, timing, cooling system, lubrication system, fuel injection (Motronic). |
| Transmission: | Clutch, gearbox, final drive (shaft drive) inspection, maintenance, and repair procedures. |
| Brakes: | ABS II (if equipped), hydraulic system, brake pad replacement, caliper service, rotor specifications. |
| Electrical: | Wiring diagrams, component testing, battery, ignition system, lighting, starter motor, charging system, diagnostic codes. |
| Chassis And Suspension: | Frame inspection, front fork (telescopic) service and overhaul, rear shock absorber (Monolever) replacement, steering head bearing adjustment. |
| Fuel System: | Fuel tank, fuel pump, fuel injectors, throttle body servicing, emissions control systems. |
| Bodywork And Trim: | Fairing removal and installation, seat, fenders, instrumentation, and general body panel maintenance. |
| Procedures Included | |
| Maintenance: | Routine service checks, oil changes, filter replacements, spark plug replacement, brake fluid flush, clutch fluid flush, drive shaft lubrication, air filter cleaning/replacement. |
| Troubleshooting: | Diagnostic flowcharts for common problems, electrical system fault finding, engine performance issues. |
| Repair And Rebuild: | Detailed step-by-step instructions for engine overhauls, transmission rebuilds, suspension component replacement, and electrical component repair. |
| Specifications: | Torque values, clearances, fluid capacities, wear limits, and diagnostic parameters. |
| Technical Depth | |
| Depth: | Comprehensive: Covers everything from basic owner maintenance to complete engine rebuilds and advanced electrical diagnostics, reflecting factory standards. |
| Manual Specifications | |
| File Format | |
| File Type: | |
| Searchability: | Typically text-searchable for efficient information retrieval. |
| Print Quality | |
| Quality: | High-resolution scans of original factory documentation, ensuring clarity of diagrams and text. |
| Binding Type | |
| Binding: | N/A (Digital PDF download) |
| Paper Type | |
| Paper: | N/A (Digital PDF download) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Four-stroke, horizontally opposed twin-cylinder (Boxer) |
| Displacement: | 1170 cc (1.17 Liters) |
| Bore X Stroke: | 101 mm x 73 mm |
| Engine Code: | M54 (specific variants may exist) |
| Valvetrain: | SOHC, 2 valves per cylinder |
| Cooling System: | Oil-cooled (with fan assist) |
| Performance | |
| Horsepower: | Approx. 61 hp (45 kW) at 5000 rpm |
| Torque: | Approx. 98 Nm (72 lb-ft) at 3000 rpm |
| Fuel System | |
| Fuel Delivery: | Electronic Fuel Injection (Bosch Motronic MA 2.4) |
| Fuel Type: | Unleaded gasoline, minimum 91 RON (95 ROZ) |
| Lubrication | |
| Oil Type: | SAE 20W-50 or SAE 15W-50 motorcycle specific engine oil (refer to manual for exact BMW recommendations) |
| Oil Capacity: | Approx. 4.0 liters (4.2 US quarts) with filter change |
| Transmission | |
| Standard | |
| Type: | 5-speed manual gearbox |
| Clutch: | Single dry plate, hydraulically operated |
| Final Drive: | Shaft drive |
| Features | |
| Gear Ratios: | Specific ratios available in manual, typically geared for relaxed cruising. |
| Final Drive Ratio: | 1:3.09 (approx.) |
| Transmission Oil: | BMW Gear Oil (refer to manual for specific grade, often SAE 75W/90 GL-5) |
| Transmission Oil Capacity: | Approx. 0.5 liters (0.53 US quarts) |
| Dimensions | |
| Exterior | |
| Length: | Approx. 2235 mm (88.0 in) |
| Width: | Approx. 820 mm (32.3 in) at handlebars |
| Height: | Approx. 1145 mm (45.1 in) at handlebars |
| Wheelbase: | Approx. 1572 mm (61.9 in) |
| Seat Height: | Approx. 760 mm (29.9 in) |
| Weights | |
| Dry Weight: | Approx. 205 kg (452 lbs) |
| Gross Vehicle Weight Rating: | Approx. 420 kg (926 lbs) |
| Fuel Tank Capacity: | 17.0 liters (4.5 US gallons), including reserve |
| Safety Features | |
| Ratings | |
| ABS: | Optional BMW Motorrad ABS II available on some models. |
| Active Features | |
| Braking System: | Dual 305 mm discs with 4-piston calipers (front), Single 285 mm disc with 2-piston caliper (rear). |
| Lighting: | Halogen headlamp, multi-reflector turn signals and taillight. |
| Passive Features | |
| Frame Construction: | Steel tube frame providing robust chassis support. |
| Technology Features | |
| Infotainment | |
| Instrument Cluster: | Analog speedometer, tachometer, digital odometer, trip meter, clock, and warning lights. Some models may have optional heated grips. |
| Driver Assistance | |
| ABS Availability: | Optional ABS II, a significant safety feature for its time. |
| Connectivity | |
| Diagnostic Port: | BMW's proprietary diagnostic connector, requiring specific tools for advanced fault code reading. |
| Maintenance | |
| Service Intervals | |
| Oil Change: | Every 10,000 km (6,000 miles) or annually, whichever comes first. |
| Valve Check And Adjust: | Every 20,000 km (12,000 miles). |
| Spark Plug Replacement: | Every 20,000 km (12,000 miles). |
| Brake Fluid Flush: | Every 2 years. |
| Clutch Fluid Flush: | Every 2 years. |
| Fluid Specifications | |
| Engine Oil Spec: | See engine_specs.lubrication.oil_type. |
| Transmission Oil Spec: | See transmission.features.transmission_oil. |
| Brake Fluid Spec: | DOT 4 brake fluid. |
| Clutch Fluid Spec: | DOT 4 brake fluid (same as brakes). |
| Known Issues | |
| Common Wear Items: | Clutch plates, brake pads, fork seals, rear shock absorber (over time). |
| Potential Electrical Gremlins: | As with many bikes of this era, electrical connections and grounds can sometimes require cleaning and dielectric grease application. |
| Transmission Noise: | Some owners report a characteristic gearbox whine, which is often normal for the design. |
| Fuel Sender Unit: | Can occasionally fail, leading to inaccurate fuel level readings. |
| Vehicle History | |
| Brand Heritage | |
| Manufacturer: | Bayerische Motoren Werke AG (BMW) |
| Heritage Focus: | Long history of engineering innovation, particularly with boxer engines and shaft drive systems in motorcycles since the 1920s. |
| Model Evolution | |
| Development Goal: | To create a stylish, comfortable cruiser that retained BMW's characteristic engineering quality and Boxer engine character. |
| Predecessors: | Drew inspiration from classic cruiser designs while leveraging BMW's established Boxer platform. |
| Production | |
| Production Period: | 1996-2005 |
| Manufacturing Location: | Berlin, Germany (BMW Motorrad plant) |
| Awards & Recognition | |
| Recognitions | |
| Market Reception: | While not focused on 'awards' in the traditional sense, the R1200C was recognized for its unique styling and capable, if understated, performance within the cruiser segment. |
| Ratings | |
| Owner Satisfaction: | Generally positive, particularly from owners who appreciated its distinct character and the Boxer engine's torque delivery. |