BMW C1 200 Instrucciones de funcionamiento

Repair manual

BMW Motorrad

After Sales

C1 200

Published by BMW Motorrad

After Sales

UX-VS-2

from the publisher.

Errors and omissions excepted. We reserve the right to introduce technical modifications at any time.

Printed in Germany 03/01

Preface

This Repair Manual is intended to assist you in performing all essential maintenance and repair operations

to a professional standard. In its role as a reference source for service personnel, it supplements and ex-

pands upon the theoretical and hands-on instruction provided at our training centres to enhance the quality

of our service.

A new edition of this manual will be issued in response to required revisions or the need to incorporate ad-

ditional information (supplements).

The illustrations and descriptions contained in this manual apply exclusively to standard, unmodified BMW

Motorcycles and/or BMW Motorcycles equipped with factory-approved BMW accessories and options.

•The Repair Manual's structure reflects the logical sequence in which the operations it describes will be

performed: removal, dismantling, repairs, assembly and installation.

•The individual chapters in this manual correspond to the motorcycle's individual assembly groups.

A reference arrow with chapter and page calls your attention to additional information contained in another

section of the manual.

e.g. a ................ Refer to Assembly Group 46

•Group "00" describes the operations carried out in the course of each Inspection. The various inspec-

tion routines are numbered I, II, III and IV. To help in maintaining a continuous, logical work sequence,

these same numerical designations are employed to identify the subsequent sections describing the ac-

tual repair operations.

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

When the need arises, repair instructions are also issued in the form of Service Information Bulletins. This

information is then incorporated into subsequent editions of the repair manual. We also recommend the

lavishly illustrated Electronic Parts Catalogue as a supplementary source of information.

When individual steps within an overall operation only apply to motorcycles with specific accessories or

optional equipment, the options to which the steps refer are identified by brackets at the start of the line,

such as [with heated grips].

Please devote your careful attention to the following pages with their explanations describing the symbols

used in the manual and their significance.

BMW Motorrad

After Sales

Published by BMW Motorrad

After Sales

UX-VS-2

80788 München

written permission.

We reserve the right to introduce technical modifications at any time. Errors and omissions excepted.

Printed in Germany

11 10.

Chap. chapter page continued

How to use this manual

Each chapter starts with a table of contents.

Following the table of contents is a table containing the techical data and specifications for the chapter's

subject.

Chapter 00 describes maintenance procedures and provides general information as well as the pre-delivery

inspection; it furnishes all torque specifications along with listings of fluids and lubricants.

Explanation of symbols

This repair manual for the C1 employs the following symbols; please refer to the table for their meanings.

Special notices for more efficient procedures

LNote:

These special notices help technicians work more efficiently when operating, inspecting, adjusting and

maintaining motorcycles.

eAttention:

Special information and precautionary notices to prevent damage to the motorcycle. Failure to observe

these mandatory precautions may invalidate the warranty.

dWarning:

Precautions intended to protect the rider and/or other individuals against injury as well as potentially fatal

hazards.

Contents

The titles of the operations described in this chapter ............. together with the page numbers

Operations

•Operations

•A dot or period identifies individual procedures described under a title

– Previous operations

– The hyphen identifies procedures described in more detail under a different title or in another chapter

Remove means:

to completely unscrew a retaining component (such as a bolt or screw)

to detach a component (such as an injection rail) and move it enough to gain access to assemblies installed

behind it (such as a throttle-valve).

Loosen means:

to unscrew an attachment (such as a bolt or screw) without removing it entirely from its threaded socket or

retainer

X Torque specifications:

These data are indicated whenever torques deviate from the standards defined in DIN EN 24 014 and

DIN 912 ISO.

00 Tightening torques operating fluids

00 Pre-delivery check

00 Maintenance

11 Engine

12 Engine electrics

13 Fuel preparation and control

16 Fuel tank and lines

17 Radiator

18 Exhaust system

21 Clutch

24 Gearbox

31 Front forks

32 Steering

>> Continuation

Contents

<< Back

Group / Chapter

33 Rear wheel drive

34 Brakes

36 Wheels and tyres

46 Frame

51 Equipment

52 Seat

61 General electrical equipment

62 Instruments

63 Lights

65 Optional extras

72 Seat belts

<< Back

>> Continuation

Group / Chapter

BMW Motorrad

Maintenance schedule

C1, C1 200

Customer Licence No. Mileage

Job Order No. Date Mechanic's signature

BMW Inspection

at 10,00 km/600 miles

BMW Maintenance

Service every

7,500 km/4,500 miles

BMW Inspection

every 15,000 km/

9,000 miles

BMW

Annual Service

MoDiTeC/DIS plus, read fault code memory

Change the engine oil while at regular operating temperature and replace the oil filter element

If the vehicle is ridden for short distances only or at outside temperatures below 0° C (32° F): every 3 months or after

every 3,000 km (1,800 miles) at the latest

Clean oil strainer and magnetic plug

Change transmission fluid

every 30,000 km/18,000 miles or 3 years*)

Inspect coolant level, top up if necessary, inspect hoses for damage, chafing points

Change the coolant

every 2 years*)

Check valve clearances and adjust if necessary *)

Replacing spark plug

Replace air filter element

shorten change interval if severely dirty or dusty

Drain condensate drain hose from air manifold

Brake hoses and connections: check condition and routing

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

Inspect brake fluid level at front/rear

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

Renew brake fluid at least once a year

Replace variator belt

Check clutch liner, replace if necessary*)

Cleaning mesh filter of variator

Grease driving variator (greased version)

Check and clean driving variator (ungreased version, replace variator if necessary)

Replace complete driving variator

every 22,500 km/14,000 miles, greased version only

Check wheel bearings for play; replace if necessary*)

Checking that leading-link mounts are free of play

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

Clean and grease the battery terminals, if necessary

Check freedom of movement of Bowden cables, check for abrasion and damage

Easy-lift mechanism:

– Check operation of mechanism and check freedom of movement

– Inspect Bowden cables for damage and signs of wear and chafing, ensuring that mechanism moves

freely without binding; check free travel and adjust as required *)

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 cable for release, belt buckles, belt strap, inertia reels, and belt locks

Check crash element for damage

Inspect shoulder bar for damage, replace deformation element if necessary*)

Replace fuel filter

every 37,500 km/22,500 miles

Only ABS: Replace seal in brake master cylinder

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

Check tightness of bolts and nuts at engine mountings and quick-release axles

Final inspection with road safety and functional check:

– Clutch engagement, steering, front and rear brake

– Condition of tyres and wheels, tyre inflation pressure

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

– If necessary, test ride

*) Write up on separate invoice; Not part of standard service procedure

UX-VS-2, 10.2001 BMW recommends Castrol

BMW Motorrad

Pre-delivery Check

C1, C1 200

Customer Registration number

Order no. Signature of mechanic

BMW

Pre-delivery Check

Inspect transportation packaging for damage

C1:

–Unpack

– Inspect for damage

–Attachparts

–Clean

Battery:

–Remove

– Pour in electrolyte

–Charge

–Greaseterminals

– Install (mark date of installation)

Inspect complete scope of supply:

– Toolkit

– Documentation

–Keys

– Scope of optional equipment

Inspect tyre inflation pressure

Pour in fuel

Operational check as final inspection:

– Engine idling

– Clutch, clutch engagement

–Steering

–Seatbelt

– Easy-lift mechanism

– Brakes, front and rear

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

–Setheadlight

– If necessary, test ride

UX-VS-2, 10.2001 BMW recommends Castrol

Order no. 01 71 0 136 450 UX-VS-2, 03.2001 Printed in Germany

Item Specified

value

Unit of measure or

specification

Oil capacities

Engine (with filter)

Gearbox

1.0 (0.22)

0.090 (0.020)

litres (Imp pints)

15W40

litres (Imp pints)

API GL 4

Coolant

Cooling system

Expansion tank

1.25 (2.2)

0.2 (0.35)

litres (Imp pints)

Mixing ratio:

Water: 50%

Antifreeze: 50%

Protection down to

–25 °C (-13 °F)

Windshield washer fluid 1.0 (1.8) litres (Imp pints)

Water and cleaning prod-

uct, antifreeze as required

Brake fluid DOT 4

Valve clearances

Measured cold, maximum 35 °C (95 °F)

Inlet: 0.05…0.14

(0.002…0.006)

Exhaust: 0.20…0.29

(0.009…0.010)

(in)

Spark plugs

Electrode gap 0.8…0.9

(0.031…0.035)

NGK CR8 EB

(in)

Idle speed 1900 rpm

Tyre pressures (tyres cold)

Solo

Full load

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 strainer to engine

Engine water drain plug

Oil filter cover

Camshaft gears to camshaft

Guide rail to camshaft support

Chain tensioner plug

Camshaft bearing bridge

Valve cover

Machine bolt TDC setting

Spark plug

Driving variator

Driving variator cover

Driven variator

Locknut of clutch to driven variator

Variator cover to power train link

Ventilation cover for variator

Front stub axle

Clamping bolts for front stub axle

Brake calliper at fork slider tube

Bleed screw in brake calliper

Cover of handbrake control

Rear stub axle, use nut only once

Exhaust to cylinder head

Auxiliary link to power train link M8

Auxiliary link to power train link M10

Silencer to auxiliary link

Suspension strut to power train link/brake calliper holder

Link mounting to power train link

Tubular link to frame

Stand to frame

Rubber element to tubular link

Cladding bolts

Hand-tight

130

2.8

Nm (Loctite 243)

BMW Motorrad

Service data

C1, C1 200

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