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 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: PDF 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....
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.