BMW C1 - Workshop Manual / Repair Manual

BMW C1 & C1 200 SERVICE MANUAL


- English Workshop Manual, to motorcycles BMW models C1 & C1 200.


INDEX:
    

PREFACE
HOW TO USE THIS MANUAL
EXPLANATION OF SYMBOLS
Contents
Operations
CONTENTS
MAINTENANCE SCHEDULE
PRE-DELIVERY CHECK
SERVICE DATA
00 TIGHTENING TORQUES OPERATING FLUIDS
TORQUE SPECIFICATIONS
TABLE OF SERVICE PRODUCTS
00 PRE-DELIVERY CHECK
CHECK TRANSPORT CONTAINER FOR DAMAGE
Damage in Germany
Damage in export markets
UNPACK C1
Place C1 on stand
Take the C1 from the stand
CHECK C1 FOR DAMAGE
CHECK PACKAGE CONTENTS TO DETERMINE WHETHER CONSIGNMENT IS COMPLETE
FILL AND CHARGE THE BATTERY
USE BMW MODITEC/DIS PLUS TO ACCESS STORED ERROR CODES
CHECK TYRE INFLATION PRESSURES
ADD FUEL
OPERATION CHECK AS FINAL INSPECTION
FINAL CLEANING
VEHICLE DELIVERY
00 MAINTENANCE
MAINTENANCE INTERVALS
1,000 km/600 miles Inspection    
BMW Service
BMW Inspection
BMW Annual Service
READING OUT BMW MODITEC/DIS AND ERROR CODES STORED IN ECU
(Inspections I, II, III and IV)
ENGINE OIL CHANGE
(Inspections I, II, III and IV)
Drain engine oil and clean magnetic plug
Clean oil filter screen
Replace oil filter element
Refill engine with oil
GEARBOX OIL CHANGE
(Inspection III, IV) every 30,000 km/18,000 miles or every 3 years    
CHECKING COOLANT
(Inspections I and III)
Adding coolant
CHANGE COOLANT
(Inspection IV, every 2 years)
Drain coolant
Draining expansion tank
Adding coolant
CHECKING VALVE CLEARANCES
(Inspections I, II and III)
Swivel out powertrain cradle
Checking valve clearances
Adjusting valve clearances
REPLACE SPARK PLUG
(Inspections II and III)
REPLACING AIR CLEANER ELEMENT
(Inspections II and III)
EMPTY DRAIN PIPE FROM INTAKE-AIR PLENUM CHAMBER
(Inspection IV)
CHECKING BRAKE LINES
(Inspections II and III)
Checking brake lines
CHECKING BRAKE SYSTEM OPERATION AND INSPECT FOR LEAKS
(Inspections II and III)
CHECKING BRAKE FLUID LEVEL
(Inspections I, II and III)
Checking fluid level in the closed brake fluid reservoir
Checking fluid level in the open brake fluid reservoir
CHECKING BRAKE PADS AND DISCS FOR WEAR/REPLACING
(Inspections II and III)
Checking brake pads for wear
Front brake pads
Rear brake pads
Replacing brake pads
Front brake
Rear brake
Checking the brake discs
REPLACING BRAKE FLUID
(Inspection IV)
Front brake
Drawing off brake fluid/forcing back brake pistons
Bleed the front brake circuit
Rear brake
Drawing off brake fluid/forcing back brake pistons
Bleeding rear brake circuit
VARIATOR DRIVE BELT REPLACEMENT
(Inspections II and III)
Check belt
CHECKING CLUTCH LINING
(Inspection III)
CLEAN VARIATOR FILTER SCREEN
(Inspections II and III)
DRIVE VARIATOR
Remove drive variator
Check, clean and grease drive variator (lubricated version)
(Inspection II, III) (lubricated version)
Check and clean drive variator (unlubricated version)
(Inspection II, III) (unlubricated version)
REPLACING COMPLETE DRIVE VARIATOR
(Inspection II) every 22,500 km (13,500 miles )   – lubricated version only
CHECKING WHEEL BEARING FLOAT
(Inspection III)
CHECK TO ENSURE THAT LEADING LINK BEARING HAS ZERO PLAY
(Inspection I, IV)
Checking steering bearing play
CHECK BATTERY ELECTROLYTE LEVEL - ADD DISTILLED WATER IF NECESSARY
(Inspection IV)
Checking battery electrolyte level
Adding distilled water
CLEAN/GREASE BATTERY TERMINALS IF NECESSARY
(Inspection IV)
CHECKING BOWDEN CABLES
(Inspections III and IV)
CHECKING EASY-LIFT MECHANISM
(Inspections I, II, III and IV)
CHECKING WINDSCREEN WASHER
(Inspections I, II and III)
CHECK WINDSCREEN WIPER
(Inspections II, III and IV)
CHECKING SAFETY ELEMENTS
(Inspections I, II, III and IV)
Check Bowden cable for central seat- belt release
Check belt straps and belt buckles
Check inertia reels
Check inertia-reel's detent mechanism to ensure that it engages correctly
EXAMINE CRASH ELEMENTS
(Inspections I, II, III and IV)
CHECK SHOULDER BAR AND DEFORMATION ELEMENT
(Inspections I, II, III and IV)
Measure shoulder bar
REPLACING FUEL FILTER
(Inspection II) every 37,500 km (22,500 miles  )
REPLACING BOOT IN BRAKE-CONTROL ASSEMBLY (MASTER CYLINDER), ONLY WITH OPTIONAL ABS
(Inspection III) every 30,000 km (18,000 miles  )
CHECK MOUNTS
(Inspection I)
FINAL INSPECTION WITH ROAD SAFETY AND OPERATION CHECK
(Inspections II, III and IV)
Tyre tread depth (recommended minimum)
Tyre pressures (tyres cold)
Roadworthiness check
11 ENGINE
C1 ENGINE
C1 LUBRICATION
C1 DRIVETRAIN
# OPERATIONS PERFORMED WITH POWERTRAIN CRADLE INSTALLED
SWIVEL OUT POWERTRAIN CRADLE
LOCK ENGINE AT TDC
# CHECKING VALVE CLEARANCES
# ADJUSTING VALVE CLEARANCES
REMOVING AND INSTALLING POWERTRAIN CRADLE
Replacing grooved ball bearing for engine mount
# Replacing ignition cover
Replacing oil pump
Removing and installing oil pump
Measuring oil pump
Water pump removal, installation, replacement
Removing water pump
Replacing shaft oil seals
Install water pump
# Replacing oil pressure switch
# Replacing oil filter
# Replacing pressure-relief (bypass) valve
# Replacing filter screen
Replacing oil seal on crankshaft
Removing crankshaft oil seal
Installing crankshaft oil seal
CYLINDER HEAD
# Dual temperature sensor removal, installation, replacement
Bucket tappet removal, installation, replacement
Inlet and exhaust valve
Removing valves
Check valve guide for wear
Check valve seat for wear
Regrinding valve seats
Check valve for wear
Check valve springs for wear
Install valves
# CHECK TIMING CHAIN
# Replacing chain tensioner
# Cylinder head cover removal and installation
Camshaft, camshaft sprocket, camshaft bearing cap
Removing and installing camshaft sprockets
Camshaft bearing cap/camshaft removal, installation, replacement
Checking camshafts
REPLACING CHAIN RAILS
Chain rail replacement
Replacing guide rail
Replacing chain tensioner rail
Timing chain removal, installation, replacement
Cylinder head removal and installation
Cylinder liner removal
Checking cylinder dimensions
Replacing stud bolts
Piston removal, installation, replacement
Replacing piston rings
Checking piston dimensions
Measuring piston pin
REMOVING CRANKSHAFT
Measuring end float
MEASURING HOUSING
Measuring main bearings
Replacing bearing shells
Removing bearing shells
Installing bearing shells
Replacing cylindrical pin for starter double gear
Installing crankshaft
Measuring end float in housing
Joining halves of crankcase
12 ENGINE ELECTRICS
REPLACING SPARK PLUG/IGNITION CABLE
Replacing spark plugs
Replacing ignition cable
REPLACING IGNITION COIL
REPLACING STARTER
REPLACING ALTERNATOR
REPLACING TDC TRIGGER
RELUCTOR REMOVAL AND INSTALLATION
Replacing one-way clutch
Replacing starter double gear
Replacing one-way clutch gear
13 FUEL PREPARATION AND CONTROL
REMOVING AND INSTALLING AIR FILTER HOUSING
REMOVING AND INSTALLING INTAKE-AIR PLENUM CHAMBER
REMOVING AND INSTALLING THROTTLE-VALVE ASSEMBLY
INJECTOR
Removing and installing injectors
Replacing injector
Replacing injection nozzle holder
REPLACING BMS CONTROL UNIT
16 FUEL TANK AND LINES
REMOVING AND INSTALLING FUEL TANK
REPLACING FUEL FILTER
FUEL PUMP UNIT
Removing, installing fuel pump assembly
17 RADIATOR
COOLANT CIRCUIT
REMOVING AND INSTALLING COOLANT HOSES
Opening hose clamps
Closing hose clamps
Replacing feed hoses to radiator
Hose between radiator and elbow
Hose between elbow and coolant pipe
Hose between elbow and refill reservoir
Vent hose
Replacing return hose to radiator
Hose between radiator and coolant pipe
Installing coolant hoses
Replacing coolant hoses on engine
Remove engine coolant hoses
Replacing coolant hoses
Replacing thermostat
Install engine coolant hoses
REMOVING AND INSTALLING COOLANT PIPES
Removing engine coolant feed pipe
Removing engine coolant return pipe
Installing coolant pipes
REPLACING VAPOUR DISCHARGE HOSE
REMOVING AND INSTALLING EXPANSION TANK
CHANGING COOLANT
Draining coolant
Drain coolant from supply line/engine
Draining coolant from return line
Draining coolant from expansion tank
Adding coolant
Add coolant to feed and return lines and engine
Filling expansion tank with coolant
Checking coolant level
CHECKING COOLING SYSTEM FOR LEAKS
REMOVING AND INSTALLING RADIATOR WITH FAN
Removing and installing front frame with radiator
Removing and installing radiator with fan shroud in front frame
Replacing radiator
Replacing fan
Replacing air duct
REPLACING REFILL RESERVOIR
18 EXHAUST SYSTEM
REMOVING AND INSTALLING SILENCER HEAT SHIELD
REMOVING AND INSTALLING SILENCER SYSTEM
REMOVING AND INSTALLING OXYGEN SENSOR
21 CLUTCH
CENTRIFUGAL COUPLING
Checking clutch
Removing/replacing clutch
Check spring
Install clutch
24 GEARBOX
C1 GEARBOX
# OPERATIONS WITH POWERTRAIN CRADLE INSTALLED
# VARIATOR REPLACEMENT
Removing variator
Removing variator driven plate
Removing variator drive plate
Installing variator
Install drive variator (lubricated version)
Install drive variator (unlubricated version)
Installing driven variator
DISASSEMBLING, CHECKING AND ASSEMBLING DRIVE VARIATOR
Dismantling drive variator
Dismantling drive variator (unlubricated version)
Dismantle drive variator (lubricated version)
Inspect individual components of drive variator
Variator cover
Checking belt
Check crankshaft journal
Check bearing tube (spacer)
Check primary external plate
Check drive wheel
Checking rollers
Check guides and spring clips for wear
Assemble drive variator
DISMANTLING, TESTING AND ASSEMBLING DRIVE VARIATOR
Checking individual components of driven variator
Check variator shaft
Dismantling driven variator
Checking individual components
Checking bearing
Replace grooved ball bearing and needle bearing for secondary inside plate
Assembling driven variator
VARIATOR - REDUCTION GEAR UNIT
Replace shaft oil seal for variator shaft in gearbox cover (shaft installed)
Dismantling and assembling gearbox, checking individual components
# Operations with powertrain cradle installed
Preparations
# Gearbox cover removal
# Gearbox shaft removal
# Replacing housing shaft oil seal on output shaft
Replacing shaft oil seal for variator shaft in gearbox cover (shaft removed)
# Replacing grooved ball bearing for variator shaft in gearbox cover
# Replacing grooved ball bearing for variator shaft in housing
# Replacing grooved ball bearing for output shaft in cover  
Replacing grooved ball bearing for output shaft in housing
# Checking dimensions of gearbox shafts
Checking and measuring variator shaft
Testing and measuring intermediate shaft
Testing and measuring output shaft
31 FRONT FORKS
REMOVING AND INSTALLING TELESCOPIC FORKS AND FORK CROSS BRACE
Removing telescopic fork
Removing and installing fixed tube
REMOVING FORK CROSS BRACE
Fork cross brace; components
Dismantling fork cross brace
Removing pot-type joints
Installing pot-type joints
Removing ball bearing with stud
Installing ball bearing and stud
Installing fork cross brace
Installing telescopic fork
REPLACING SEAL RINGS FOR TELESCOPING TUBE
Removing telescopic tube cross brace with telescopic tubes
Replacing telescopic tube seal
Remove seal
Install seal
Replace seal telescopic tube/seal holder
Remove seal holder
Install seal holder
Replace guide bush
Replacing telescopic tube
Replacing telescopic tube cross brace
Replacing ball joint
Installing telescopic tube cross brace with telescopic tubes
MEASURING TELESCOPIC FORK
Examining telescoping tube cross brace and fork cross brace
Checking runout of fixed tube
REMOVING AND INSTALLING FRONT SPRING STRUT
REPLACING SPRING/SHOCK ABSORBER
REMOVING AND INSTALLING LEADING LINK
Removing leading link
Replacing left and right taper- fit ball bearings for leading link
Installing leading link
32 STEERING
GENERAL VIEW OF HANDLEBAR
HEATED GRIPS
Heated grip, removing and installing on left side
Heated grip, removing and installing on right
REMOVING AND INSTALLING LEFT/RIGHT BRAKE-CONTROL ASSEMBLIES
REPLACING LEFT/RIGHT BRAKE LAMP SWITCH
REPLACING SEAL IN BRAKE UNIT (MASTER CYLINDER) WITH OPTIONAL ABS ONLY
REMOVING AND INSTALLING LEFT AND RIGHT HANDLEBAR LEVERS
REMOVING AND INSTALLING HANDLEBAR
REPLACING THROTTLE CABLE
33 REAR WHEEL DRIVE
AUXILIARY SWING ARM
Removing auxiliary swing arm
Replacing Silentblocks
Installing auxiliary swing arm
REMOVING AND INSTALLING LEFT/ RIGHT SPRING STRUT
REPLACING SPRING/SHOCK ABSORBER
34 BRAKES
BRAKE CALIPER BACKPLATE
Removing brake-caliper carrier
Replacing brake caliper carrier bearing
Replacing rubber bush
Installing brake-caliper carrier
FRONT BRAKE CALIPER
Removing and installing brake caliper
REAR BRAKE CALIPER
Removing and installing rear brake caliper
REMOVING AND INSTALLING FRONT BRAKE DISC
REMOVING AND INSTALLING REAR BRAKE DISC
FRONT ABS WHEELSPEED SENSOR, REMOVAL AND INSTALLATION
REPLACING FRONT ABS RELUCTOR
REMOVING AND INSTALLING REAR ABS SENSOR
REPLACING REAR ABS RELUCTOR
CHECKING AND ADJUSTING ABS WHEELSPEED SENSOR GAP
Front wheel
Rear wheel
REMOVING AND INSTALLING ABS CONTROL UNIT
REMOVING AND INSTALLING FRONT BRAKE LINES/HOSES
Replacing front brake hose – without ABS
Removing front brake lines/hoses – (with ABS)
Brake hose between front wheel and brake line, ABS control unit
Brake line between brake hose, front wheel and ABS control unit
Brake line between brake hose, right brake handlebar fitting and ABS control unit
Brake hose between right brake handlebar fitting and brake line, ABS control unit
Installing front brake lines/hoses – (with ABS)
REMOVING AND INSTALLING REAR BRAKE LINES/HOSES
Brake hose between brake unit on left and brake line
Brake line between brake hose, left brake-control assembly, and brake hose to brake caliper - wit...
Brake lines between brake hose, left brake-control assembly, and brake hose to brake caliper - wi...
Brake lines between brake hose, brake handlebar fitting and ABS control unit
Brake lines between ABS control unit and brake hose to brake caliper
Brake hose between brake line and brake caliper
CHECKING BRAKE PADS AND DISCS FOR WEAR/REPLACING
Checking brake pads for wear
Front brake pads
Rear brake pads
Replacing brake pads
Front brake
Rear brake
Checking the brake discs
CHECKING BRAKE FLUID LEVEL
Checking fluid level in the closed brake fluid reservoir
Checking fluid level in the open brake fluid reservoir
REPLACING BRAKE FLUID AND BLEEDING BRAKE SYSTEM
Front brake
Drawing off brake fluid/forcing back brake pistons
Bleeding front brake circuit
Rear brake
Drawing off brake fluid/forcing back brake pistons
Bleeding rear brake circuit
36 WHEELS AND TYRES
REMOVING AND INSTALLING FRONT WHEEL
REPLACING WHEEL BEARINGS
Removing left/right wheel bearings
Installing right/left wheel bearings
REMOVING AND INSTALLING REAR WHEEL
Removing rear wheel
Installing rear wheel
STATIC BALANCING OF FRONT AND REAR WHEELS
Static balancing of front wheel
Static balancing of rear wheel
CHECKING FRONT/REAR WHEEL RIM FOR RUNOUT
Checking front wheel rim for runout
Checking rear wheel rim for runout
46 FRAME
C1 - TRIM OVERVIEW
C1 - Trim mount
Removing and installing front trim
Running board cover removal and installation
Left and right lower panel removal, installation, replacement
Panel centre section removal, installation, replacement
Rear side trim removal, installation, replacement
Service hatch removal and installation
Rear storage compartment cover
Replacing seal on rear storage compartment
Replacing battery compartment
Remove the rear storage compartment
Upper tunnel removal, installation, replacement
Left/right tunnel removal, installation, replacement
Side panel removal, installation, replacement
Replacing plaque for side panel
C-pillar inner trim removal, installation, replacement
Shoulder bar external trim, removal, installation, replacement
Shoulder bar crash element, left or right, removal and installation
C-pillar foam element, removal, installation, replacement
Rear trim removal, installation, replacement
Instrument trim removal, installation and replacement
Impact panel removal, installation, replacement
Lower handlebar cover
Replacing badge
Crash element trim removal, installation, replacement
Crash element removal, installation, replacement
Replacing holder for crash element
Knee trim removal, installation, replacement
Licence plate bracket removal, installation, replacement
Rear mudguard removal, installation, replacement
LARGE STORAGE COMPARTMENT
Replacing cover
Storage compartment removal and installation
Replacing the power socket
ROOF REMOVAL AND INSTALLATION
WINDSCREEN REMOVAL AND INSTALLATION
Cross brace foam element; removal, installation, replacement
ROOF BAR REPLACEMENT
SHOULDER BAR REPLACEMENT
CHECKING SHOULDER BAR ALIGNMENT
ARTICULATED JOINT MECHANISM
Overview
Removing and installing articulated joint mechanism
Articulated joint hand lever mechanism removal and installation
Large hand lever removal and installation
Small hand lever removal/installation
Replacing control disc for large hand lever
REPLACE STAND BOWDEN CABLES
Removing Bowden cable for retracting stand
Removing Bowden cable for extending stand
Bowden cable installation/adjustment
STAND
Overview
Removing/installing stand
Stand bearings
Overview, left
Overview, right
Greasing the bearings
Replacing tension spring(s)
Lobe/overload guard transfer element replacement
Replacing stand switch
POWERTRAIN CRADLE
Overview
Removing powertrain cradle mounts
Coupling for swing arm bearing
Replacing bearing sleeve, right
Replacing left/right bush
Tubular swing arm
Removing and installing spacer bush for tubular swing arm
Replacing left/right bearing bushings for tubular swinging arm
Replacing right/left Silentblocs for tubular swing arm
Installing powertrain cradle mounts
REAR FRAME MEMBER REPLACEMENT
LUGGAGE SYSTEM BRACKET
Bracket removal and installation
Upper bracket removal and installation
Support base removal and installation
Luggage system lock carrier removal and installation
Luggage hook replacement
TOPCASE
Hinge replacement
Replacing inside lock
51 EQUIPMENT
REMOVING IGNITION SWITCH/ STEERING LOCK
REPLACING SEAT LOCK
REAR STORAGE COMPARTMENT LOCK BARREL REPLACEMENT
REPLACING LOCK BARREL ON LARGE/SMALL STORAGE COMPARTMENT
REPLACING TOPCASE LOCK BARREL
REPLACING LOCK BARREL ON LUGGAGE RAIL
MIRROR REMOVAL AND INSTALLATION
MIRROR BRACKET REMOVAL AND INSTALLATION
52 SEAT
SEAT REMOVAL, INSTALLATION, REPLACEMENT
Open the seat
Remove seat
Heated seat removal, installation, replacement
Install seat
BACKREST REMOVAL, INSTALLATION, REPLACEMENT
HEAD RESTRAINT REMOVAL, INSTALLATION, REPLACEMENT
Replacing badge
SEAT LOCK REPLACEMENT
Seat lock Bowden cable removal and intallation
61 GENERAL ELECTRICAL EQUIPMENT
WIRING HARNESS
General view, from right
General view, from front
Replacing wiring harness
Wiring harness section plug connections
Adapter cable for optional equipment
WIPE/WASH SENSOR
Replacing wipe/wash sensor
COMBINATION SWITCH
Combination switch, left, removal and installation
Combination switch, right, removal and installation
BATTERY
Remove the battery
Filling and charging the battery
Installing the battery
VOLTAGE REGULATOR
Replacing voltage regulator
STARTER RELAY
Replacing starter relay
REMOVING AND INSTALLING WIPE/WASH PUMP AND REPLACING FLUID RESERVOIR
Replacing intake strainer
Removing and installing filler funnel
Replacing filler strainer
FILLER HOSE
Removing and installing filler hose
REMOVING AND INSTALLING DELIVERY HOSE
Hose between pump and interface at front windscreen
Hose between interface at front windscreen and spray nozzles
REPLACING SPRAY NOZZLES
ADJUSTING SPRAY NOZZLES
REPLACING PASSAGE IN FRONT WINDSCREEN
WIPER MOTOR REPLACEMENT
REMOVING AND INSTALLING WIPER ARMS
62 INSTRUMENTS
INSTRUMENT CLUSTER
Wiring colours
Removing and installing instrument panel
Replacing wiring harness
Fuel gauge replacement
Speedometer replacement
Indicator and warning lights
Replacing bulbs
63 LIGHTS
HEADLIGHT
Removing and installing headlight
Replacing intermediate frame
Replacing headlight bezel
Replacing high-beam/low- beam bulb
Replacing parking light bulb
Checking headlight beam angle
Height adjustment
Lateral adjustment
TURN SIGNAL
Replacing front left/right turn signal
Replacing front left/right turn signal bulb
Replacing left/right rear turn signal
Replacing rear left/right turn signal bulb
REAR LIGHTS
Replacing taillamp cluster
Replacing bulb for brake light/ rear light
MAP LIGHT
Map light bulb replacement
65 OPTIONAL EXTRAS
ALARM SYSTEM (DWA)
Service and maintenance notice
Applies to all service and maintenance operations
When working with BMW MoDiTeC/DIS plus diagnostic system
Activating and checking operation of alarm system
Activating the system
Deactivating the immobilizer
Supplementary (manual) activation of the alarm function (with immobilizer already active)
Deactivating the immobilizer and alarm functions
Programming the alarm system
Activating the programming mode
Programming the system
Programming the system to mode B
Indicator LED replacement
Control unit replacement
Receiver replacement
Motion sensor replacement
Replacing alarm system bracket
FUN AUDIO SYSTEM
Volume control replacement
Amplifier replacement
Speaker removal, installation, replacement
Replacing left/right speaker brackets
Audio module replacement
72 SEAT BELTS
SEAT BELTS
Removing and installing central belt release mechanism
Checking operation of central belt release mechanism
Inertia reel replacement
Replacing Bowden cable with belt buckles on left/right
Replacing indicator switches for seat belt
Replacing 3-point seat belt
Replacing 2-point seat belt
REPLACING GUIDE FOR SEAT BELT AT SHOULDER BAR