BMW C1 Betriebsanleitung

Repair Manual

BMW AG Motorcycle Division

After Sales

Published by: © BMW AG Motorcycle Division

After Sales

UX-VS-2

permission.

Errors and omissions excepted; subject to technical amendment.

Produced in Germany 12/99

Introduction

This repair manual will help you to perform all the main maintenance and repair work correctly and efficient-

ly. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and prac-

tical knowledge acquired at the BMW Training Centre. It is a contribution towards achieving even higher

Service quality.

A new issue of this repair manual will be published if amendments or additions (supplements) are needed.

All information in both text and illustrations refers to motorcycles in standard condition or with genuine

BMW accessories installed, and not to motorcycles which have been modified in any way to depart from

the manufacturer’s specification.

•The repair manual is structured in the logical sequence of the work to be performed: Removal, Disas-

sembly,Repair, Assembly, Installation.

•The entire contents are divided into individual chapters, corresponding to the Construction Groups.

An arrow symbol followed by the chapter and page numbers is a reference to another chapter,

e.g. Ób ............................................See Group 46

•Work to be performed during an Inspection is described in Group “00”. The various inspection routines

are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that

work can take place without interruption.

•Use of the BMW special tools needed for certain tasks is described in the work instructions.

If the need arises, repair instructions are also issued in the form of Service Information. This information is

of course incorporated into the next issue of the repair manual. We also recommend, as an additional sour-

ce of information, the Electronic Parts Catalogue (ETC), which contains clear and easy-to-follow illustrati-

ons.

If the work described here is restricted to a particular equipment specification, for instance if a specific op-

tional extra (OE) is fitted, this is stated in square brackets at the start of the item concerned, e.g. [With heat-

ed handlebar grips].

Please refer to the following pages as well for a description of other symbols used and how to work with it.

BMW AG, Motorcycle Division

After Sales

Published by: BMW AG Sparte Motorrad

After Sales

UX-VS-2

D - 80788 München

permission.

Errors and omissions excepted; subject to technical amendment.

Produced in Germany

11 10.

Chapter Page number within chapter

Usage

Each chapter starts with the list of contents.

The list of contents is followed by the Technical Data table.

Chapter 00 “Maintenance and general instructions”details the handover checklist and lists all tightening

torques and operating fluids.

Key to symbols

In this Workshop Manual for the C 1 model, the following symbols are used; their meanings are explained

in the table.

Special instructions aimed at improving the work procedures.

LNote:

Specific information on operating, inspecting and adjusting work for the motorcycle as well as maintenance

procedures.

eCaution:

Instructions and precautions specifically intended to prevent damage to the motorcycle. Failure to comply

with them could invalidate the warranty.

dWarning:

This symbol stands for precautions and measures which are essential in order to protect the rider or other

persons from possibly severe or fatal injury.

Contents

Headlines for the work described in the chapter................. with the relevant page number

Activities

•Activities

•The bullet symbol means that work steps are described in greater detail under another headline

–Preceding activities

–A line indicates work steps described in greater detail under another headline or in another chapter

If the term “release”or “remove”is used:

the fastener (e.g. screw) must be slackened off and taken out

a component (e.g. fuel rail) must be removed to the extent that other components which it conceals (e.g.

throttle-valve rail) are accessible

If the term “loosen”or “slacken”is used:

the fastener (e.g. screw) must only be slackened off but not taken out

X Tightening torques:

Values are stated if they differ from DIN EN 24 014 or DIN 912 ISO industrial standards.

Contents

Group / Chapter Page

00 Maintenance and general instructions ................................................... 00.1

11 Engine ............................................................................................ 11.1

12 Engine electrics ..................................................................................... 12.1

13 Fuel preparation and control.................................................................. 13.1

16 Fuel tank and lines................................................................................. 16.1

17 Radiator ............................................................................................ 17.1

18 Exhaust system ..................................................................................... 18.1

31 Front forks ............................................................................................ 31.1

32 Steering ............................................................................................ 32.1

33 Rear wheel drive.................................................................................... 33.1

34 Brakes ............................................................................................ 34.1

Contents

Group / Chapter Page

36 Wheels and tyres................................................................................... 36.1

46 Frame ............................................................................................ 46.1

51 Equipment ............................................................................................ 51.1

61 General electrical equipment ................................................................. 61.1

62 Instruments ........................................................................................... 62.1

63 Lights ............................................................................................ 63.1

72 Seat belts ............................................................................................ 72.1

Order No. 01 71 0 010 174 UX-VS-2, November 1999 Printed in Germany

Customer Licence plate No.

Order No. Mechanic's signature

BMW

Pre-delivery check

Check the shipping pallet for damage

C1:

–Unpack

–Inspect for damage

–Install remaining items

–Clean

Battery:

–Remove

–Fill with acid

–Charge

–Grease terminal posts

–Install (mark with installation date)

Check that the delivery is complete:

–Toolkit

–Documentation

–Motorcycle keys

–Optional extras

Check tyre pressures

Fill fuel tank

Final inspection as functional check:

–Engine idle

–Clutch, engagement at pull-away

–Steering

Seat belts

Easy-lift

–Front and rear brakes

–Lights and signalling equipment, telltale and warning lights, instruments

–Adjust headlight beam

–If necessary, test ride

BMW AG Motorcycle Division

Pre-delivery check

Order No. 01 71 0 010 174 UX-VS-2, November 1999 Printed in Germany

Customer Licence plate No.

Order No. Mechanic's signature

BMW Inspection

at 1,000 km

(600 miles)

BMW Service

7,500 km

(4,500 miles)

BMW Inspection

every 15,000 km

(9,000 miles)

BMW Annual

Service

MoDiTeC, read fault code memory

Renew the oil filter element

Change the engine oil while at regular operating temperature; renew the oil filter element

If the C1 is ridden only for short distances or at outside temperatures below 0°C, this task must be performed every

3 months, or at least every 3,000 km (1,800 miles)

Clean oil strainer and the magnetic oil drain plug

Change gearbox oil every 30,000 km (18,000 miles)*)30,000 3

Check the coolant level and restore to correct level if necessary, check hoses for damage and chaffing

Change coolant (every two years) 2

Check valve clearances, adjust if necessary*)

Renew the spark plug

In very dirty and dusty operating conditions, replace air-filter element at more frequent intervals

Empty drain pipe from air manifold

Brake hoses and connections: check condition and routing

Check operation of brake system and check for leaks; repair/replace as necessary*)

Check brake fluid level at front and rear

Examine brake pads and discs for wear, replace if necessary*)

Change brake fluid at least once a year*)

Replace variator belt

Check clutch liner, replace if necessary*)

Clean strainer (filter) of variator

Grease driving variator

Replace driving variator assembly every 22,500 km (13,500 miles) 22,500

Check wheel bearings for play, replace if necessary*)

Check that leading link bearing has zero play

Battery: Check battery acid level, if necessary add distilled water

Clean and grease the battery terminals, if necessary

Check Bowden cables (for damage, chaffing and stiff action)

Easy-lift mechanism: check operation of mechanism and check freedom of movement

Check windscreen washer system; adjust nozzles if necessary and top up washer fluid in reservoir

Check windscreen wiper; replace wiper blade if necessary*)

Safety elements: Check Bowden cable of release, belt buckles, belt webbing, inertia reels, belt stop

Check crash element for damage

Check shoulder bars for damage; replace deformation element if necessary*)

Replace fuel filter (every 37,500 km/22,500 miles) 37,500

Replace rubber element of master brake cylinder ABS, initially complete fitting

(every 30,000 km/18,000 miles) 30,000

Check security of screws and nuts of engine mounts and quick-release axles

Final inspection with road safety and functional check:

– Clutch engagement at pull-away, steering, brakes front and rear, condition of tyres and wheel rims, tyre

pressures

– Lights and signalling equipment, telltale and warning lights, instruments

–Ifnecessary,testride

*)To be billed as separate items, associated work: see brochure on flat-rate units motorcycle 2000

BMW AG Motorcycle Division

Maintenance schedule

Order No. 01 71 0 010 244 UX-VS-2, 11.99 Printed in Germany

Item Desired value Unit of

measurement/

specification

Oil capacities

Engine (with filter)

Gearbox

1.0 (1.76)

0.090 (0.16)

litres (Imp. pints)

15W40

litres (Imp. pints)

API GL 4

Coolant

Cooling system

Expansion tank

1.2 (2.11)

0.2 (0.35)

litres (Imp. pints)

Composition:

Water: 50%

Antifreeze: 50%

Antifreeze protection

to –25 °C

Windcreen-washer fluid 1.0 (1.76) Water and cleaning agent;

antifreeze as necessary

Brake fluid DOT 4

Valve clearances

Measured cold (max. 35 °C)

Inlet: 0.05-0.14

(0.002-0.006)

Exhaust: 0.20-0.29

(0.008-0.011)

mm (in)

Spark plug

Electrode gap 0.7...0.8

(0.027...0.031)

NGK CR8 EB

mm (in)

Idle speed 1,900 rpm

Tyre pressure (cold tyres)

solo

fully loaded

front/rear

1.9/2.1 (27.6/30.5)

1.9/2.4 (27.6/34.8)

bar (psi)

Tightening torques:

Engine oil drain plug

Oil mesh filter on engine

Engine water drain plug

Oil filter cap

Camshaft sprockets to camshafts

Guide rail to camshaft mount

Screw plug for chain tensioner

Camshaft bearing cap

Valve cap

Machine screw for locating crankshaft at TDC

Spark plug

Variator, driving

Cover for driving variator

Variator, driven

Locknut, clutch to driven variator

Variator cover to drive swinging arm

Ventilation cover for variator

Front quick-release axle

Clamping screws for front quick-release axle

Brake calliper at fork slider tube

Bleed screw in brake calliper

Cover of handbrake fitting

Rear quick-release axle Never re-use nut

Exhaust to cylinder head

Secondary swinging arm to drive swinging arm, M8

Secondary swinging arm to drive swinging arm, M10

Silencer to secondary swinging arm

Spring strut to drive swinging arm/brake calliper holder

Swinging-arm bearing to drive swinging arm

Tubular swinging arm to frame

Stand to frame

Rubber element to tubular swinging arm

Screws for trim panels

Hand-tight

130

Nm (Loctite 243)

BMW AG Motorcycle Division

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