BMW C1 y C1 200 - Manual de Taller - Service Manual - Manuel Reparation
BMW c1 & c1 200
SERVICE MANUAL - MANUEL REPARATION - REPARATURANLEITUNG
BMW C1 & C1 200 SERVICE MANUAL - Multilanguage (English, Español, Deutsch, Français, Italiano, Nederlands, Português) Repair Manual, to motorcycles BMW models C1 & C1 200. CONTENTS: 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
BMW C1 y C1 200 - Manual de Taller - Service Manual - Manuel Reparation
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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