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C1 200
BMW C1 200 User Manual
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31.8
Fork cross brace; components
1
Stop ring on pot-type joint bearing
2
Dust boot, upper pot-type joint bearing
3
Pot-type joint bearing
4
Fork cross brace
5
Lock ring
6
Fork cross brace bearing
7
Spacer sleeve
8S
t
u
d
9
Dust boot, lower pot type joint bearing
31 42 528
Dismantling fork cross brace
Removing pot-type joints
•
Remove dust boot
(2)
•
Remove stop ring (1)
C1310070
8
6
3
4
5
7
2
1
9
C1310080
9
1
2
3
227
229
Table of Contents
00 Tightening Torques Operating Fluids
11
Default Chapter
11
Table of Contents
11
Torque Specifications
13
11 Engine
13
12 Engine Electrical System
14
13 Fuel Injection System
14
16 Fuel Tank
14
17 Cooling System
14
Silencer (Muffler)
15
21 Clutch
15
24 Gearbox
15
31 Front Forks
16
32 Steering
16
33 Final-Drive Unit
17
34 Brakes
17
36 Wheels
18
46 Frame
18
51 Equipment
19
52 Seats
20
61 Electrical Equipment
20
62 Instruments
21
63 Lights
21
65 Optional Extras
21
72 Seat Belts
21
Table of Service Products
22
00 Pre-Delivery Check
25
Check Transport Container for Damage
27
Damage in Export Markets
27
Damage in Germany
27
Unpack C1
28
Place C1 on Stand
29
Take the C1 from the Stand
31
Check C1 for Damage
33
Check Package Contents to Determine Whether Consignment Is Complete
33
Fill and Charge the Battery
34
Add Fuel
35
Check Tyre Inflation Pressures
35
Operation Check as Final Inspection
35
Steering
35
Use BMW Moditec/Dis Plus to Access Stored Error Codes
35
Final Cleaning
36
Vehicle Delivery
36
00 Maintenance
37
Maintenance Intervals
41
1,000 Km/600 Miles Inspection
41
BMW Service
41
BMW Annual Service
41
Reading out BMW Moditec/Dis and Error Codes Stored in ECU
41
(Inspections I, II, III and IV)
41
Engine Oil Change
42
(Inspections I, II, III and IV)
42
Drain Engine Oil and Clean Magnetic Plug
42
Clean Oil Filter Screen
42
Replace Oil Filter Element
42
Refill Engine with Oil
43
Gearbox Oil Change
43
(Inspection III, IV) Every 30,000 Km/18,000 Miles or Every 3 Years
43
Checking Coolant
44
(Inspections I and III)
44
Adding Coolant
44
Change Coolant
45
(Inspection IV, Every 2 Years)
45
Drain Coolant
45
Draining Expansion Tank
45
Adding Coolant
45
Checking Valve Clearances
46
(Inspections I, II and III)
46
Swivel out Powertrain Cradle
46
Checking Valve Clearances
48
Adjusting Valve Clearances
49
Replace Spark Plug
52
(Inspections II and III)
52
Replacing Air Cleaner Element
53
(Inspections II and III)
53
Empty Drain Pipe from Intake-Air Plenum Chamber
53
(Inspection IV)
53
Checking Brake System Operation and Inspect for Leaks
54
Checking Brake Lines
54
(Inspections II and III)
54
Checking Brake Fluid Level
54
(Inspections I, II and III)
54
Checking Fluid Level in the Closed Brake Fluid Reservoir
54
Checking Fluid Level in the Open Brake Fluid Reservoir
55
Checking Brake Pads and Discs for Wear/Replacing
56
(Inspections II and III)
56
Checking Brake Pads for Wear
56
Front Brake Pads
56
Rear Brake Pads
56
Replacing Brake Pads
57
Front Brake
57
Rear Brake
58
Checking the Brake Discs
59
Replacing Brake Fluid
60
(Inspection IV)
60
Front Brake
60
Drawing off Brake Fluid/Forcing Back Brake Pistons
60
Bleed the Front Brake Circuit
61
Rear Brake
61
Drawing off Brake Fluid/Forcing Back Brake Pistons
61
Bleeding Rear Brake Circuit
62
Variator Drive Belt Replacement
62
(Inspections II and III)
62
Check Belt
63
Checking Clutch Lining
64
(Inspection III)
64
Clean Variator Filter Screen
64
(Inspections II and III)
64
Drive Variator
65
Remove Drive Variator
65
Check, Clean and Grease Drive Variator (Lubricated Version)
65
(Inspection II, III) (Lubricated Version)
65
Check and Clean Drive Variator (Unlubricated Version)
67
(Inspection II, III) (Unlubricated Version)
67
Replacing Complete Drive Variator
68
(Inspection II) Every 22,500 Km (13,500 Miles) - Lubricated Version Only
68
Checking Wheel Bearing Float
69
(Inspection III)
69
Check Battery Electrolyte Level - Add Distilled Water if Necessary
70
(Inspection IV)
70
Checking Battery Electrolyte Level
70
Adding Distilled Water
71
Check to Ensure that Leading Link Bearing Has Zero Play
70
(Inspection I, IV)
70
Checking Bowden Cables
71
(Inspections III and IV)
71
Clean/Grease Battery Terminals if Necessary
71
(Inspection IV)
71
Checking Windscreen Washer
72
(Inspections I, II and III)
72
Checking Safety Elements
72
(Inspections I, II, III and IV)
72
Check Bowden Cable for Central Seat-Belt Release
72
Check Belt Straps and Belt Buckles
72
Check Inertia Reels
72
Check Inertia-Reel's Detent Mechanism to Ensure that It Engages Correctly
72
Check Windscreen Wiper
72
(Inspections II, III and IV)
72
Examine Crash Elements
73
(Inspections I, II, III and IV)
73
Check Shoulder Bar and Deformation Element
73
Measure Shoulder Bar
73
Replacing Fuel Filter
73
(Inspection II) Every 37,500 Km (22,500 Miles )
73
Replacing Boot in Brake-Control Assembly (Master Cylinder), Only with Optional ABS
74
(Inspection III) Every 30,000 Km (18,000 Miles )
74
Check Mounts
75
(Inspection I)
75
Final Inspection with Road Safety and Operation Check
75
(Inspections II, III and IV)
75
Tyre Tread Depth (Recommended Minimum)
75
Tyre Pressures (Tyres Cold)
75
Roadworthiness Check
75
11 Engine
77
C1 Engine
85
C1 Lubrication
86
C1 Drivetrain
87
Swivel out Powertrain Cradle
88
Operations Performed with Powertrain Cradle Installed
88
Lock Engine at TDC
90
Checking Valve Clearances
91
Adjusting Valve Clearances
92
Removing and Installing Powertrain Cradle
93
Replacing Grooved Ball Bearing for Engine Mount
95
Replacing Ignition Cover
95
Replacing Oil Pump
96
Removing and Installing Oil Pump
96
Measuring Oil Pump
97
Water Pump Removal, Installation, Replacement
97
Removing Water Pump
97
Replacing Shaft Oil Seals
98
Install Water Pump
99
Replacing Oil Filter
100
Replacing Filter Screen
101
Removing Crankshaft Oil Seal
101
Installing Crankshaft Oil Seal
101
Cylinder Head
102
Dual Temperature Sensor Removal, Installation, Replacement
102
Bucket Tappet Removal, Installation, Replacement
102
Inlet and Exhaust Valve
103
Check Valve Guide for Wear
105
Check Valve Seat for Wear
106
Regrinding Valve Seats
106
Check Valve for Wear
107
Check Valve Springs for Wear
107
Check Timing Chain
109
Replacing Chain Tensioner
109
Cylinder Head Cover Removal and Installation
110
Camshaft, Camshaft Sprocket, Camshaft Bearing Cap
111
Removing and Installing Camshaft Sprockets
111
Camshaft Bearing Cap/Camshaft Removal, Installation, Replacement
112
Checking Camshafts
114
Replacing Chain Rails
114
Chain Rail Replacement
114
Replacing Guide Rail
115
Replacing Chain Tensioner Rail
115
Timing Chain Removal, Installation, Replacement
116
Cylinder Head Removal and Installation
116
Cylinder Liner Removal
117
Checking Cylinder Dimensions
117
Replacing Stud Bolts
118
Piston Removal, Installation, Replacement
118
Replacing Piston Rings
119
Checking Piston Dimensions
120
Measuring Piston Pin
120
Removing Crankshaft
121
Measuring End Float
121
Measuring Housing
122
Measuring Main Bearings
122
Replacing Bearing Shells
122
Removing Bearing Shells
122
Installing Bearing Shells
123
Replacing Cylindrical Pin for Starter Double Gear
124
Installing Crankshaft
124
Measuring End Float in Housing
124
Joining Halves of Crankcase
125
12 Engine Electrics
127
Technical Data
129
Replacing Spark Plug/Ignition Cable
131
Replacing Spark Plugs
131
Replacing Ignition Cable
132
Replacing Ignition Coil
132
Replacing Alternator
133
Replacing Starter
133
Reluctor Removal and Installation
134
Replacing One-Way Clutch
136
Replacing Starter Double Gear
136
Replacing One-Way Clutch Gear
137
Replacing TDC Trigger
134
13 Fuel Preparation and Control
139
Removing and Installing Air Filter Housing
141
Removing and Installing Intake-Air Plenum Chamber
141
Removing and Installing Throttle-Valve Assembly
143
Injector
144
Removing and Installing Injectors
144
Replacing Injector
144
Replacing BMS Control Unit
145
Fuel Tank and Lines
147
17 Radiator
157
Technical Data
159
Coolant Circuit
161
Removing and Installing Coolant Hoses
163
Opening Hose Clamps
163
Closing Hose Clamps
163
Replacing Feed Hoses to Radiator
163
Hose between Radiator and Elbow
163
Hose between Elbow and Coolant Pipe
163
Hose between Elbow and Refill Reservoir
164
Vent Hose
164
Replacing Return Hose to Radiator
164
Hose between Radiator and Coolant Pipe
164
Installing Coolant Hoses
164
Removing and Installing Coolant Pipes
166
Removing Engine Coolant Feed Pipe
166
Installing Coolant Pipes
167
Replacing Vapour Discharge Hose
168
Removing and Installing Expansion Tank
169
Changing Coolant
170
Draining Coolant
170
Drain Coolant from Supply Line/Engine
170
Draining Coolant from Return Line
171
Draining Coolant from Expansion Tank
171
Adding Coolant
171
Add Coolant to Feed and Return Lines and Engine
171
Filling Expansion Tank with Coolant
172
Checking Coolant Level
172
Checking Cooling System for Leaks
172
Removing and Installing Radiator with Fan
174
Removing and Installing Radiator with Fan Shroud in Front Frame
174
Replacing Radiator
175
Replacing Fan
175
Replacing Air Duct
175
Replacing Refill Reservoir
176
21 Clutch
185
Technical Data
187
Centrifugal Coupling
189
Checking Clutch
189
Removing/Replacing Clutch
189
Check Spring
190
24 Gearbox
193
Technical Data
195
C1 Gearbox
197
Variator Replacement
198
Removing Variator
198
Removing Variator Driven Plate
198
Removing Variator Drive Plate
199
Installing Variator
200
Installing Driven Variator
201
Operations with Powertrain Cradle Installed
198
Disassembling, Checking and Assembling Drive Variator
202
Dismantling Drive Variator
202
Dismantle Drive Variator (Lubricated Version)
202
Inspect Individual Components of Drive Variator
203
Variator Cover
203
Checking Belt
203
Check Crankshaft Journal
203
Check Bearing Tube (Spacer)
203
Check Primary External Plate
203
Check Drive Wheel
204
Checking Rollers
204
Check Guides and Spring Clips for Wear
205
Assemble Drive Variator
205
Dismantling, Testing and Assembling Drive Variator
206
Checking Individual Components of Driven Variator
206
Check Variator Shaft
206
Dismantling Driven Variator
207
Checking Individual Components
207
Checking Bearing
208
Replace Grooved Ball Bearing and Needle Bearing for Secondary Inside Plate
208
Assembling Driven Variator
209
Variator - Reduction Gear Unit
210
(Shaft Installed)
210
Dismantling and Assembling Gearbox, Checking Individual Components
211
Operations with Powertrain Cradle Installed
211
Preparations
211
Gearbox Cover Removal
212
Gearbox Shaft Removal
212
Replacing Housing Shaft Oil Seal on Output Shaft
213
Replacing Shaft Oil Seal for Variator Shaft in Gearbox Cover
214
(Shaft Removed)
214
Checking Dimensions of Gearbox Shafts
218
Checking and Measuring Variator Shaft
218
Testing and Measuring Intermediate Shaft
219
Testing and Measuring Output Shaft
219
31 Front Forks
221
Technical Data
223
Removing and Installing Telescopic Forks and Fork Cross Brace
225
Removing Telescopic Fork
225
Removing Fork Cross Brace
227
Fork Cross Brace; Components
228
Dismantling Fork Cross Brace
228
Removing Pot-Type Joints
228
Replacing Telescopic Tube Seal
233
Replace Seal Telescopic Tube/Seal Holder
234
Remove Seal Holder
234
Install Seal Holder
234
Replace Guide Bush
235
Replacing Telescopic Tube
236
Replacing Telescopic Tube Cross Brace
237
Replacing Ball Joint
238
Installing Telescopic Tube Cross Brace with Telescopic Tubes
238
Measuring Telescopic Fork
239
Examining Telescoping Tube Cross Brace and Fork Cross Brace
239
Checking Runout of Fixed Tube
239
Replacing Spring/Shock Absorber
243
Removing and Installing Leading Link
243
Removing Leading Link
243
32 Steering
247
Technical Data
249
General View of Handlebar
251
Heated Grip, Removing and Installing on Left Side
252
Heated Grips
252
Heated Grip, Removing and Installing on Right
253
Removing and Installing Left/Right Brake-Control Assemblies
254
Replacing Left/Right Brake Lamp Switch
255
Replacing Seal in Brake Unit (Master Cylinder)
256
With Optional ABS Only
256
Removing and Installing Handlebar
257
Replacing Throttle Cable
259
33 Rear Wheel Drive
261
Technical Data
263
Auxiliary Swing Arm
265
Installing Auxiliary Swing Arm
265
Removing Auxiliary Swing Arm
265
Removing and Installing Left/Right Spring Strut
266
Replacing Spring/Shock Absorber
267
Table of Contents
320
Default Chapter
342
Licence Plate Bracket Removal, Installation, Replacement
342
Rear Mudguard Removal, Installation, Replacement
342
Large Storage Compartment
343
Replacing Cover
343
Storage Compartment Removal and Installation
343
Replacing the Power Socket
344
Windscreen Removal and Installation
345
Cross Brace Foam Element; Removal, Installation, Replacement
346
Roof Removal and Installation
345
Roof Bar Replacement
347
Shoulder Bar Replacement
349
Checking Shoulder Bar Alignment
350
Articulated Joint Mechanism
351
Overview
351
Articulated Joint Hand Lever Mechanism Removal and Installation
355
Large Hand Lever Removal and Installation
355
Small Hand Lever Removal/Installation
357
Replacing Control Disc for Large Hand Lever
359
Replace Stand Bowden Cables
360
Bowden Cable Installation/Adjustment
362
Stand
363
Overview
363
Removing/Installing Stand
363
Stand Bearings
365
Overview, Left
365
Overview, Right
365
Greasing the Bearings
366
Replacing Tension Spring(S)
366
Lobe/Overload Guard Transfer Element Replacement
366
Replacing Stand Switch
367
Powertrain Cradle
368
Overview
368
Removing Powertrain Cradle Mounts
370
Coupling for Swing Arm Bearing
370
Replacing Bearing Sleeve, Right
370
Replacing Left/Right Bush
370
Tubular Swing Arm
371
Removing and Installing Spacer Bush for Tubular Swing Arm
371
Replacing Left/Right Bearing Bushings for Tubular Swinging Arm
372
Installing Powertrain Cradle Mounts
373
Luggage System Bracket
374
Bracket Removal and Installation
374
Upper Bracket Removal and Installation
375
Support Base Removal and Installation
375
Luggage System Lock Carrier Removal and Installation
376
Luggage Hook Replacement
376
Topcase
377
Hinge Replacement
377
Replacing Inside Lock
377
52 Seat
387
Default Chapter
389
Heated Seat Removal, Installation, Replacement
389
Install Seat
389
Open the Seat
389
Remove Seat
389
Backrest Removal, Installation, Replacement
390
Head Restraint Removal, Installation, Replacement
390
Replacing Badge
390
Seat Lock Replacement
391
Seat Lock Bowden Cable Removal and Intallation
391
Table of Contents
394
Hose between Pump and Interface at Front Windscreen
409
Removing and Installing Delivery Hose
409
Hose between Interface at Front Windscreen and Spray Nozzles
410
Adjusting Spray Nozzles
411
Replacing Spray Nozzles
411
Replacing Passage in Front Windscreen
412
Wiper Motor Replacement
412
Removing and Installing Wiper Arms
414
Technical Data
425
Headlight
427
Height Adjustment
429
Lateral Adjustment
430
Turn Signal
430
Rear Lights
432
Map Light
434
65 Optional Extras
435
Alarm System (DWA)
437
Service and Maintenance Notice
437
Applies to All Service and Maintenance Operations
437
When Working with BMW Moditec/Dis Plus Diagnostic System
437
Activating and Checking Operation of Alarm System
437
Activating the System
437
Deactivating the Immobilizer
438
Supplementary (Manual) Activation of the Alarm Function (with Immobilizer Already Active)
438
Deactivating the Immobilizer and Alarm Functions
438
Programming the Alarm System
439
Activating the Programming Mode
439
Programming the System
440
Programming the System to Mode B
440
Indicator LED Replacement
441
Control Unit Replacement
441
Receiver Replacement
442
Motion Sensor Replacement
443
Replacing Alarm System Bracket
444
Fun Audio System
445
Volume Control Replacement
445
Amplifier Replacement
446
Speaker Removal, Installation, Replacement
446
Replacing Left/Right Speaker Brackets
447
Audio Module Replacement
448
Seat Belts
451
Checking Operation of Central Belt Release Mechanism
452
Inertia Reel Replacement
452
Replacing Bowden Cable with Belt Buckles on Left/Right
453
Replacing Indicator Switches for Seat Belt
453
Replacing 3-Point Seat Belt
454
Replacing 2-Point Seat Belt
456
Replacing Guide for Seat Belt at Shoulder Bar
457
4
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BMW C1 200 Specifications
General
Brand
BMW
Model
C1 200
Category
Motorcycle
Language
English
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