BMW C1 Repair Manual
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BMW C1 Repair Manual

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Repair Manual
C 1
BMW AG Motorcycle Division
After Sales

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Summary of Contents for BMW C1

  • Page 1 Repair Manual BMW AG Motorcycle Division After Sales...
  • Page 2 Published by: © BMW AG Motorcycle Division After Sales UX-VS-2 All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission. Errors and omissions excepted; subject to technical amendment. Produced in Germany 12/99...
  • Page 3 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.

  • Page 4: Key To Symbols

    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;...

  • Page 5: Table Of Contents

    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 ....................
  • Page 6 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...
  • Page 7 BMW AG Motorcycle Division Pre-delivery check Customer Licence plate No. Pre-delivery check Order No. Mechanic's signature Check the shipping pallet for damage C 1: – Unpack – Inspect for damage – Install remaining items – Clean Battery: – Remove –...

  • Page 8: Maintenance Schedule

    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)
  • Page 9 BMW AG Motorcycle Division Service data Item Desired value Unit of measurement/ specification Oil capacities Engine (with filter) 1.0 (1.76) litres (Imp. pints) 15W40 Gearbox 0.090 (0.16) litres (Imp. pints) API GL 4 Coolant Cooling system 1.2 (2.11) litres (Imp. pints) Expansion tank 0.2 (0.35)

  • Page 11: 00 Maintenance And General Instructions

    00 Maintenance and general instructions Tightening torques and Table of operating fluids Instructions for handover to customer Maintenance Contents Page Tightening torques ........................7 Table of operating fluids ......................27 00.1...

  • Page 12: Instructions For Handover To Customer

    Filling and charging the battery ..................33 Checking the C1 for damage ....................34 Checking that delivery is complete ..................34 Reading the fault code memory with the BMW MoDiTeC/DIS plus ....34 Checking tyre pressures ......................34 Fuelling .............................35 Final inspection and function check ................35...
  • Page 13 Maintenance Contents - Maintenance Page Key to maintenance intervals ....................37 Reading out MoDiTeC/DIS plus fault memory ............37 (Inspections I, II, III and IV) ........................37 Engine oil change ........................38 (Inspections I, II, III and IV) ........................38 Cleaning oil strainer and magnetic plug ................38 (Inspections I, II, III and IV) ........................38 Changing gearbox oil...
  • Page 14 Contents - Maintenance Page Checking brake pads for wear ....................50 Front brake pads ..........................50 Rear brake pads ..........................50 Replacing brake pads .........................51 Front brake ............................51 Rear brake ............................52 Checking the brake discs ......................53 Renewing brake fluid ........................53 (Inspection IV) ...........................53 Front brake ............................54 Drawing off brake fluid/forcing back brake pistons ................54...
  • Page 15 Contents - Maintenance Page Checking Bowden cables ......................62 (Inspections I, II, IV) ..........................62 Bowden cable for easy-lift: .......................62 Throttle cable: ..........................62 Checking headlight beam angle ..................62 (Inspection IV) ...........................62 Checking windscreen washer .....................63 (Inspections I, II, III and IV) ........................63 Checking windscreen wiper ....................63 (Inspections II, III and IV) ........................63...
  • Page 16 00.6...

  • Page 17: 11 Engine

    Tightening torques Model Connection 11 Engine Oil drain plug, magnetic Threaded plug, oil strainer Oil filter cover Threaded plug for locking at TDC Alternator Alternator cover Ignition trigger, Tapite screw 6 Loctite 243 Holder for alternator cable, Tapite screw 6 Loctite 243 Magnetic rotor to crankshaft, thread-locking 30 Loctite 243 compound...
  • Page 18 Model Connection Cylinder head Cylinder head cover Collar nut 30 ±1 Securing screw Spark plug Camshaft gears, thread-locking compound 30 Loctite 243 Bearing cap Chain guide, thread-locking compound 10 Loctite 243 Plug for chain tensioner Vent screw Dual temperature sensor, thread-locking 15 Loctite 243 compound Housing...

  • Page 19: 12 Engine Electrics

    Model Connection 12 Engine electrics Spark plug Ignition coil to frame 00.9...

  • Page 20: 13 Fuel Preparation And Control

    Model Connection 13 Fuel preparation and control Fastener, fuel filter clamp Holder for injection nozzle (self-tapping) 4 Loctite 243 Pressure regulator clamp BMS control unit Intake manifold Air filter housing (inner/outer) Fastener for throttle cable 00.10...
  • Page 21 Model Connection 16 Fuel tank Holder, fuel tank to frame Union nut (fuel-pump unit) 00.11...

  • Page 22: Radiator

    Model Connection 17 Cooling system Bracket for seat latch, right, to frame Bracket for seat latch, left, to frame Expansion tank to frame upright Front frame to cross-tie Air duct to fan shroud Radiator to front frame Air duct to fan shroud Fan shroud to radiator Air duct to front frame Filler bowl to front frame...
  • Page 23 Model Connection 18 Silencer (muffler) Shield to holder Exhaust pipe to cylinder head Silencer to secondary swinging arm Oxygen sensor to silencer 00.13...
  • Page 24 Model Connection 31 Telescopic fork Fork bridge to frame (threaded stud), 83 LOCTITE 243 thread-locking compound Leading link to slider-tube bridge, thread-locking com- 127 LOCTITE 243 pound Holder for brake line to fork bridge Fork stanchion to fork bridge Handlebar to fork bridge Fasteners for leading-link shafts Clamp screws for leading-link shafts Spring strut to leading link...

  • Page 25: 32 Steering

    Model Connection 32 Steering Fastener for handlebar fitting Clamp screw for brake lever fitting Brake line to brake lever fitting Handlebar to fork bridge Locknut for handlebar lever pivot pin 00.15...

  • Page 26: 33 Rear Wheel Drive

    Model Connection 33 Rear wheel drive Top fastener for spring strut Bottom fastener for spring strut 00.16...

  • Page 27: Brakes

    Model Connection 34 Brakes Brake calliper to fork slider tube Banjo bolt to brake calliper Bleed screw in brake calliper Hexagon nut on drive axle (rear wheel) use once only 130 Fastener, secondary swinging arm to brake-calliper 60 LOCTITE 243 carrier M10, thread-locking compound Fastener, secondary swinging arm to brake-calliper carrier M8...
  • Page 28 Model Connection 36 Wheels Quick-release axle, thread-locking compound 83 LOCTITE 243 Quick-release axle clamp screws Brake calliper to fork slider tube Hexagon nut on drive axle (rear wheel) Use once only Fastener, secondary swinging arm to brake-calliper 60 LOCTITE 243 carrier M10, thread-locking compound Fastener, secondary swinging arm to brake-calliper carrier M8...
  • Page 29 Model Connection 46 Frame Body panels to body panels Trim panels to frame Seat to frame Lightweight foam element to frame Lightweight foam element to transverse carrier Seat to frame Intake air silencer to rear mudguard Mirror bracket to frame Mirror to mirror bracket Cover of mirror arm Roof/windscreen to transverse member...
  • Page 30 Model Connection Parking mechanism Toggle-lever mechanism to frame Stand to frame Switch (parking mechanism) stand to frame Spring holder (parking mechanism) to frame Bowden cable retaining bracket to frame Locknut for Bowden cable Secondary swinging arm to drive swinging arm Eye bolt to frame Shoulder bar Shoulder bar, top, to frame M10...

  • Page 31: Equipment

    Model Connection 51 Equipment Ignition lock to frame Fastener for seat latch Fastener, seat lock to rear side panel, left Fastener, lock tongue to lock barrel Fastener, lock barrel to cover 00.21...
  • Page 32 Model Connection 52 Seat Seat to frame 00.22...
  • Page 33 Model Connection 61 Electrical equipment Fastener, battery cable to battery Battery lead to starter relay Control-current cable to starter relay Voltage regulator to frame BMS control unit to frame Wipe/wash sensor to frame Earth cable to frame Wiper arms Clamp, cable harness to frame Horn to frame Windscreen wiper motor to frame Auxiliary shaft, wiper motor...

  • Page 34: Instruments

    Model Connection 62 Instruments Instrument cluster to instrument panel Cable clamp to instrument cluster Cable terminal to instrument cluster 00.24...

  • Page 35: Lights

    Model Connection 63 Lights Lens for turn indicator Front turn indicator to fairing Turn indicator to number-plate carrier Headlight frame Rear light 00.25...

  • Page 36: Seat Belts

    Model Connection 72 Seat belts Inertia reel to frame Belt buckle to belt-buckle mount Belt-buckle mount to frame Secondary mudguard 00.26...

  • Page 37: Table Of Operating Fluids

    Table of operating fluids Item Order number Quantity Lubricant Staburags NBU 30 PTM High-performance lubricating paste 07 55 9 056 992 75 g tube Optimoly MP 3 High-performance lubricating paste 07 55 9 062 476 100 g tube Optimoly TA High-temperature assembly paste 18 21 9 062 599 100 g tube Silicone grease 300,...
  • Page 38 83 19 9 407 855 500 ml spray housings Crack testing agent for aluminium Developer MR 70 81 22 9 407 495 500 ml spray housings Installation aids Cooling components before BMW cooling spray 83 19 9 407 762 300 ml spray assembly 00.28...

  • Page 39: Check The Shipping Pallet For Damage

    Check the shipping pallet for In case of damage in importer markets damage • Note the damage on the delivery slip • The country-specific regulations apply • When the C 1 arrives, check the crate immedi- In case of doubt, address queries to: ately for damage and if necessary examine the Bavaria Wirtschaftsagentur GmbH shipment for consequential damage...

  • Page 40: Unpacking The C1

    C1pdi01 Unpacking the C1 • Open the packaging at the openings for the straps (enlarge the openings) on left and right • Cut open along the line as shown (the line indi- cates the location of the strap) • Remove the packaging...
  • Page 41 C1pdi03 • • Operate the easy-lift and lift the C 1 onto its Disengaging and removing the straps • stand Remove the transverse brace, transportation brace C1pdi04 C1pdi05 • Centre the handlebars • Raise lever (1) of the easy-lift mechanism –...
  • Page 42 Use a ramp, for example the ramp from a motor- cycle lifting platform • Push the C1 off the pallet toward the rear Caution: Remove any nails projecting from the base of the packing or lying on the base or on the floor.

  • Page 43: Filling And Charging The Battery

    C1pdi08 Filling and charging the battery Charge current (amps) ......10 % of rated battery capacity (Ah) • • Open the lid of the stowage compartment Check the acid level and, if necessary, top up • Remove the battery cover with distilled water to the upper level mark •...

  • Page 44: Checking The C1 For Damage

    Connect the diagnosis unit to the diagnosis plug • If the parts that are needed do not appear in the Read out the fault memory • electronic parts list, please consult the C1 support Carry out any repairs specified • team at UX-VS-2 Reinstall the backrest...

  • Page 45: Fuelling

    Fuelling Final cleaning • • Open the seat Clean the C 1 • Fuel the vehicle Final inspection and function check Note: Do not use a steam or high-pressure water jet. The high steam or water pressure could damage seals, the hydraulic system or electrical components.

  • Page 46: Handing Over The Vehicle

    Handing over the vehicle This is the ideal opportunity to familiarise the cus- tomer with the C 1 in order to ensure the customer's satisfaction and safety • The following points must be demonstrated and explained to the customer: – documentation and stowage space –...

  • Page 47: Key To Maintenance Intervals

    Reading out MoDiTeC/DIS plus fault memory — Inspection at 1,000 km (600 miles) — BMW Service at 7,500 km (4,500 miles) — BMW Inspection at 15,000 km (9,000 miles) III — BMW Annual Service (Inspections I, II, III and IV) •...

  • Page 48: Engine Oil Change

    Add oil up to the “MAX” mark on the dipstick • Run the engine briefly, then stop it, check oil lev- • Secure the oil guide, BMW No. 11 7 661, to the el again and add more oil if necessary • exhaust Check coolant, top up if necessary •...

  • Page 49: Checking Coolant

    Checking coolant Adding coolant – Remove the backrest C1000050 C1000060 • Remove cap (1) from expansion tank (2). Note: Check coolant level only when the engine is cold Caution: • Open the seat and check the coolant level Add coolant only when engine is cold. Add coolant to expansion tank only if a small quan- Maximum level ..........

  • Page 50: Changing Coolant

    Changing coolant Adding coolant (Inspection IV) every 2 years Draining coolant – Remove front fairing panel – Unfasten radiator cap C1170290 • Pour coolant into filler neck C1000070 • Slip hose (arrow) over screw head • Remove drain plug • Drain coolant Note: Renew sealing ring on drain plug...

  • Page 51: Checking Valve Clearances

    Checking valve clearances (Inspections I, II and III) Moving drive swinging arm clear • Secure front wheel C1000110 • Remove lines from clips: • Injector • Air temperature sensor • Idle actuator • Coolant temperature sensor to cylinder head C1000090 •...
  • Page 52 BMW No. 00 1 580, at adapter. • Slightly raise vehicle with lifter • Install fixture, BMW No. 33 1 531, between left spring strut and drive swinging arm • Remove fastener at bottom of right spring strut at brake calliper holder Caution: Swing drive swinging arm max.

  • Page 53: Checking Valve Clearances

    Note down the valve clearances • If necessary, replace bucket tappets C1000150 Table of valve clearances • Open hose clamp (arrow) with pliers, BMW No. 17 5 500 IV left EV left • right right Remove screws (1) securing valve cover Sp.

  • Page 54: Adjusting Valve Clearances

    Adjusting valve clearances • Turn engine by turning camshafts until tips of cam lobes point outwards C1130010 • Slacken off the hose clip (arrow) at the intake air silencer. C1000180 • Use a coloured marker to highlight the TDC mark (arrow) on the inlet camshaft gear Note: Fasteners of chain guide are secured with thread-...

  • Page 55: Removing And Installing Camshaft Bearing Cap/Camshaft

    Caution: The marks on the sprockets must be in line • Slacken timing chain and install pin, BMW No. 11 7 531, instead of chain tensioner Note: • Reinstall screw Use a marker to highlight the marks on the inlet •...

  • Page 56: Replacing Spark Plug

    Caution: • Remember to remove the crankshaft locating Disconnect spark plug cap • screw. Use spark-plug wrench, BMW No. 12 3 531, to remove spark plug Operating fluids: Chain rail ..........Loctite 243 Tightening torque: Spark plug ........... 15 Nm Tightening torques: Camshaft bearing cap ........

  • Page 57: Renewing Air Cleaner Element

    Renewing air cleaner element Emptying drain pipe from air manifold (Inspections II and III) (Inspections I, II, III and IV) • Empty the drain from the air cleaner housing C1130010 C1000130 • Remove fasteners (1) securing cover of air filter housing •...

  • Page 58: Checking Brake Lines

    Checking brake lines • Turn the handlebars to full left-hand lock (Inspections II and III) Note: The volume of the brake fluid (MIN/MAX) is sufficient for lining thicknesses from new to the wear limit. It is Caution: not normally necessary to top up the fluid to accom- Refer to notes on the hazards involved in handling modate lining wear.

  • Page 59: Checking Fluid Level With Brake Fluid Reservoir Open

    Checking fluid level with brake fluid reservoir open The procedure for checking the level in the left brake fluid reservoir is described below. The procedure for checking the level in the right brake fluid reservoir is analogous. Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid de- stroys paint.

  • Page 60: Checking Brake Pads And Discs For Wear/Replacing

    Checking brake pads and discs for Rear brake pads wear/replacing Checking brake pads for wear Warning: Brake pad thickness must not fall below the mini- mum value. Always replace pads as a complete set. Front brake pads C1340360 • Visually inspect the brake pads from behind –...

  • Page 61: Replacing Brake Pads

    If the brake pads/pistons cannot be forced back in this way, there may be some other fault in the brake • system. Remove retaining pin (1) using drift or pliers, BMW No. 34 1 541 • Remove the brake pads When installing: •...

  • Page 62: Rear Brake

    Remove fastener (1) from bottom of spring strut and tie the spring strut up out of the way • Remove retaining pin (2) using pliers, BMW No. 34 1 541 • Caution: Lift out the brake pads toward the rear Avoid damaging or scratching the brake calliper;...

  • Page 63: Checking The Brake Discs

    Checking the brake discs Renewing brake fluid • Carefully check the brake discs for cracking, damage, deformation and scoring (Inspection IV) Caution: Protect trim panels against contact with brake fluid Caution: Refer to notes on the hazards involved in handling brake fluid Caution: For safety reasons, the brake fluid must be changed...

  • Page 64: Front Brake

    Front brake Bleeding the front brake circuit – Add brake fluid up to the top of the sight glass • Connect the brake bleeding device to the bleed screw on the brake calliper • Caution: Open the bleed screw by half a turn Do not allow brake fluid to come into contact with painted parts of the vehicle as brake fluid destroys paint.

  • Page 65: Rear Brake

    Rear brake When installing: • Installation is the reverse of the removal proce- dure – Add brake fluid up to the top of the sight glass Caution: – Bleed the rear brake circuit • Do not allow brake fluid to come into contact with Check the function of the brake system painted parts of the vehicle as brake fluid destroys paint.

  • Page 66: Replacing Variator Belt

    C1000240 C1000260 • Remove fasteners (1) • • Remove ventilation cover Using holder, BMW No. 11 7 521, release fas- tener of driven variator • Press variator plates together and turn them counter-clockwise • Remove belt complete with driven variator •...

  • Page 67: Checking Clutch Lining

    Checking clutch lining When installing: The wording on the belt must be legible from the outside (Inspections II and III) C1000270 C1110540 • Make sure the belt is correctly seated • Install belt complete with driven variator • • Check by turning variator manually, to ensure Remove bell housing;...

  • Page 68: Cleaning Mesh Filter Of Variator

    C1000290 • Remove mesh filter from retaining lugs and clean Note: The nut is secured with a thread-locking compound • Using holder, BMW No. 11 7 521, release fas- tener • Remove outer plate and driving variator with spacer C1110490 •...

  • Page 69: Replacing Complete Driving Variator

    20 g (0.7 oz.) of grease and install rollers • • Lightly grease O-ring and install Using holder, BMW No. 11 7 521, loosen outer • Mount spring clips and shoes on driver and plate and remove driving variator with spacer •...

  • Page 70: Checking Wheel Bearing Play

    Checking wheel bearing play When installing: • Spray shaft with lubricant Materials: Shaft ........ Klüber paste 46 MR 401 (Inspections I, II and III) Fastener, driving variator ...... Loctite 243 Note: Caution: Check bearing play only when cold. Make sure that belt is not trapped between the belt •...

  • Page 71: Checking That Leading-Link Mounts Are Free Of Play

    Checking that leading-link mounts Checking battery acid level, adding are free of play distilled water if necessary (Inspections I, II, III and IV) (Inspections II, III and IV) Checking steering bearing play • Relieve load on front wheel Warning: Battery acid is highly caustic. Protect your eyes, face, hands, clothing and the paintwork.

  • Page 72: Adding Distilled Water

    Checking Bowden cables Adding distilled water (Inspections I, II, IV) • Check Bowden cables for damage due to chaff- • Check freedom of movement and adjust, if nec- essary ........... See Group 32 Bowden cable for easy-lift: • The small lever must move up and down be- tween the two limit stops C1610030 Throttle cable:...

  • Page 73: Checking Windscreen Washer

    Checking windscreen washer Checking windscreen wiper (Inspections I, II, III and IV) (Inspections II, III and IV) • Check wiper blade for cracks • Check action of wiper arms • Check windscreen wiper and replace wiper blade, if necessary 45° ...........

  • Page 74: Checking Safety Elements

    Pull firmly on belt strap and make sure that inertia reel locks 72 5 501 C1720050 • Use test gauge, BMW No. 72 5 501, to preten- sion release lever • Engage seat belts in their buckles with an audi- ble click •...

  • Page 75: Examining Crash Element

    Examining crash element Checking body panels and fairing • Examine foam-rubber element from below for damage and cracks; replace if necessary ........... See Group 46 (Inspection IV) • Checking shoulder bars and Reinstall all body panels removed beforehand • Check that panel-to-panel gaps are correct deformation element •...

  • Page 76: Replacing Fuel Filter

    17 5 500 13 3 010 13 3 010 C1160090 • Use a clamp, BMW No. 13 3 010, to close off the fuel lines • Open hose clamp with pliers, BMW No. 17 5 500 • Replace fuel filter •...

  • Page 77: Replacing Rubber Diaphragm Of Brake Master Cylinder (30,000 Km/ 18,000 Miles) Vehicles With Abs Only

    Replacing rubber diaphragm of brake master cylinder (30,000 km/ 18,000 miles) Vehicles with ABS only 00.67...

  • Page 78: Checking Security Of Threaded Fasteners

    Check security of screws and nuts: – Exhaust mountings Caution: – Secondary swinging arm Remove the vehicle stand, BMW No. 00 1 570. – Engine mounts • – Engine mount and mount of tubular swinging arm Check wheels and tyres •...
  • Page 79 11 Engine Contents Page Technical Data ..........................5 C 1 Engine ............................13 C 1 Lubrication ..........................14 C 1 Drive ............................15 C 1 Gearbox ........................... 16 Work with engine installed ....................17 Checking valve clearances ....................... 17 Adjusting valves ..........................
  • Page 80 Contents Page Removing variator .........................34 Installing variator ...........................35 Installing inner plate of driving variator ....................35 Installing driven variator ........................36 Disassembling and assembling driving variator ............37 Checking belt ............................37 Disassembling, checking and assembling driving variator ........37 Checking individual components of driving variator .............38 Checking rollers ..........................38 .................................38...
  • Page 81 Contents Page # Replacing chain tensioner ....................57 Removing cylinder head ......................57 # Removing cylinder head cover ....................57 Removing camshaft gears .........................58 Replacing guide rail ...........................58 Replacing chain guides ......................58 Replacing guide rail ...........................58 Replacing chain tensioning rail ......................58 Removing and installing or replacing timing chain ................59 # Replacing cylinder head .........................59 Removing cylinder ..........................60 Checking cylinder dimensions ......................60...
  • Page 82 11.4...
  • Page 83 Technical Data Engine, general Single-cylinder four-stroke, double overhead camshafts driven by roller chain, 4 valves operat- ed by bucket tappets, liquid-cooled cylinder and cylinder head, integral water pump, automatic transmission. Type 1 cylinder, four-stroke Engine number Variator housing output shaft Number of cylinders Stroke mm (in) 50 (1.97)
  • Page 84 Technical Data Permissible oil consumption (miles per 0.01 Imp. pint/ miles per US quart) Gearbox oil capacity 0.090 (Imp. (0.16/0.10) pint/US quart) Crank gear Main bearing bore diameter On installation mm (in) Wear limit mm (in) 32.07 (1.26) Crankshaft - main bearing play On installation mm (in) 0.030 ...
  • Page 85 Technical Data Camshaft Inlet ° Exhaust ° Bearing cap Bearing bore diameter mm (in) 18.01...18.03 (0.709...0.7099) Wear limit mm (in) 18.05 (0.710) Inlet camshaft Bearing journal diameter mm (in) 17.969...17.980 (0.7074... 0.7078) Wear limit mm (in) 17.96 (0.707) Exhaust camshaft mm (in) 17.969...17.980 (0.7074...
  • Page 86 Technical Data Valve seat angle Inlet ° Exhaust ° Included angle between valves Inlet ° Exhaust ° Valve seat width Inlet mm (in) 1.185...1.215 (0.0466...0.0478) Wear limit mm (in) 2 (0.0787) Checking dimension mm (in) 1.0...1.4 (0.0394...0.0551) Exhaust mm (in) 1.385...1.415 (0.0545...0.0557) Wear limit mm (in)
  • Page 87 Technical Data Piston pin Outside diameter mm (in) 14.997...15.000 (0.5904...0.5906) Wear limit mm (in) 14.99 (0.5902) Installed clearance Wear limit mm (in) 0.04 (0,0016) Radial play mm (in) 0.005...0.018 (0.0002...0.0007) Wear limit mm (in) 0.03 (0.0528) Piston-pin bore diameter mm (in) 15.003...15.008 (0.5907...0.5909) Wear limit mm (in)
  • Page 88 Technical Data Cylinders Bore Cylinder mm (in) “A”: 56.388..56.398 (2.2200..2.2204) mm (in) “B”: 56,402..56.412 (2.2206..2.2209) Timing chain Wear limit Distance from sealing face to piston of chain mm (in) 6 (0.236) tensioner Water pump Water-pump shaft bearing in housing mm (in) 10.05...10.07 (0.395...0.396) Wear limit mm (in)
  • Page 89 Technical Data Output shaft Permissible run-out measured between tips mm (in) 0.06 (0.002) Bearing journal, gearbox cover, grooved ball bearing mm (in) 14.983...14.994 (0.5899...0.5903) Wear limit mm (in) 14.98 (0.589) Bearing journal, housing, grooved ball bearing mm (in) 24.984...24.993 (0.9836...0.9840) Wear limit mm (in) 24.97 (0.983)
  • Page 90 11.12...

  • Page 91: C 1 Engine

    C 1 Engine R11C160-Motor 11.13...

  • Page 92: C 1 Lubrication

    C 1 Lubrication R11C161-Schmierung 11.14...

  • Page 93: C 1 Drive

    C 1 Drive R24C161-TSS 11.15...

  • Page 94: C 1 Gearbox

    C 1 Gearbox R24C160-TSS 11.16...

  • Page 95: Work With Engine Installed

    Work with engine installed Left side • Spark plug • Oil pressure switch • Driving variator, front • Centrifugal coupling • Driven variator, rear • Gearbox • Starter motor • Temperature sensor Right side • Timing-chain tensioner • Chain guide C1110020 •...

  • Page 96: Adjusting Valves

    11 34 004 Moving drive swinging arm clear • Secure front wheel. • Position lifter, BMW No. 00 1 570 with BMW No. 00 1 580, underneath frame section. C1110050 • Release coolant hose from clip at injector and holder (arrow) at variator cover.
  • Page 97 For the sake of clarity, these illustrations show the vehicle with the drive swinging arm removed. When installing: • Install the cylinder head cover before installing the drive swinging arm. Caution: When installing, note the correct positions of the spring struts. Note: C1000150 Make sure the long lever of the parking mechanism...
  • Page 98 2.80 2.80 2.80 2.80 measured (old) C1000230 • Remove screw for chain tensioner, insert stud, BMW No. 11 7 531, in tapped bore and reinstall Bucket, screw. measured 2.85 2.75 (new) Note: The camshafts can also be removed and installed complete with the camshaft gears.

  • Page 99: Checking Camshafts

    C1110100 • Check height of cams. • Check bearing play of camshafts with Plasti- gage, BMW No. 00 2 590. C1110110 Wear values: Cam height, inlet ....min. 33.00 mm (1.230 in) Cam height, exhaust ..min. 32.15 mm (1.266 in) Installed clearance ..max. 0.100 mm (0.0039 in)

  • Page 100: Removing Drive Swinging Arm

    Removing drive swinging 11 00 060 Caution: Remember to remove stud, BMW No. 11 7 531. – Remove left service cover. • Install chain tensioner. – Remove the right rear side section. Operating fluids: Loctite ..............243 Tightening torque Fastener for chain guide....... 10 Nm Camshaft gears ...........
  • Page 101 Support the weight of the vehicle on car jack po- distributor. sitioned beneath frame. • • Remove silencer (muffler) Secure bow, BMW No. 11 0 651, to drive swing- • Open cable tie for ABS sensor cable to second- ing arm. ary swinging arm. •...

  • Page 102: Replacing Grooved Ball Bearing For Engine Mount

    Replacing grooved ball bearing for When installing: 1 Add coolant. engine mount 2 Slacken vent plug in cylinder head until liquid emerges, then retighten vent plug. – Housing halves separated • 3 Pour in remainder of coolant. Using a pipe D=24.5 mm or a19 mm socket and 4 Briefly operate engine and correct coolant level working from the inside, press out the bearing.

  • Page 103: Replacing Ignition Trigger Cover

    Replacing ignition trigger Replacing alternator 11 11 015 12 11 070 cover – Remove ignition trigger cover. – Remove the right rear side section. • Drain engine oil. • Remove fastener securing silencer to secondary swinging arm. • Slacken fasteners securing exhaust to cylinder head.

  • Page 104: Removing And Installing Magnetic Wheel

    Coat threads of self-tapping screws with Loctite Bring crankshaft to TDC. prior to installation (Tapite screws) – Insert pin, BMW No. 11 7 651, to secure crank- • Note direction of installation for trigger. shaft in this position.............See Group 00 Operating fluids: Securing screw ........
  • Page 105 When installing: • Remove all traces of old thread-locking com- pound from the threads. C1110240 • Install securing screw with washer: coat threads of securing screw with Loctite 243. C1110230 Operating fluids: • Install Woodruff key parallel to crankshaft (arrow), Screw............

  • Page 106: Replacing Freewheel

    12 11 077 Replacing freewheel Replacing starter double gear – Remove cover. – Remove magnetic wheel. C1110260 C1110250 • Check bearing bore • • Clamp the bottom of the magnetic housing in a Check teeth for distortion, wear and chipping. •...

  • Page 107: Replacing Freewheel Gear

    Replacing oil pump Replacing freewheel gear 11 11 300 Removing and installing oil pump – Remove magnetic wheel. C1110270 • Measure bearing bore. • Check teeth for distortion, wear and chipping. C1110280 • Check friction face for wear. • Wear values: Turn crankshaft until securing screws (arrows) Inside diameter....max.

  • Page 108: Measuring Oil Pump

    When installing: Measuring oil pump • The outer rotor bears a punch mark for identifica- tion. C1110300 • Check tooth edges of oil pump gear for deforma- C1110290 tion. • Measure protrusions of needle roller. • Check runout of oil pump gear relative to shaft. •...

  • Page 109: Removing And Installing Or Replacing Water Pump

    Caution: Install shaft sealing rings with flats facing each other. • Note: Use drift, BMW No. 11 7 611, and spacing ring Working from left side of engine, slide a plastic rod to install first sealing ring. • into the water pipe and use it to remove the pump Install second sealing ring without spacing ring.

  • Page 110: Replacing Oil Pressure Switch

    11 41 200 • Turn water pump shaft by hand and make sure it rotates easily and smoothly. C1000030 C1110330 • Secure drain, BMW No. 11 7 661, on exhaust pipe. • • Install thrust washer (1). Remove securing screws. •...

  • Page 111: Replacing Oil Pressure Regulating Valve

    Replacing oil pressure Replacing oil mesh strainer 11 11 296 regulating valve – Drain the oil. C1110360 C1110350 • Remove threaded plug. • Remove and clean oil mesh strainer. • • Remove threaded plug. Clean threaded plug. • Remove valve housing (3), spring (2), ball (1). •...

  • Page 112: Replacing Variator

    • Variator cover removed. • Insert pin, BMW No. 11 7 651, to secure crank- shaft in TDC position. Caution: Make sure that belt and belt pulleys remain free of oil and grease.

  • Page 113: Installing Variator

    Degrease threads of crankshaft. • • Remove outer plate from crankshaft. Install outer plate. • Hold with holder, BMW No. 11 7 521, or use in- sert pin, BMW No. 11 7 651. • Apply thread-locking compound to threads of nut. Operating fluids: Bearing tube (spacer) ..Klüber paste 46 MR 401...

  • Page 114: Installing Driven Variator

    Installing driven variator Note: Press up and at the same time turn upper belt plate Caution: clockwise to push belt inwards between the two Installed position of belt: wording to the outside. plates. • Lay belt in position between the two belt contact faces.

  • Page 115: Disassembling And Assembling Driving Variator

    • Remove all traces of old thread-locking com- pound from the threads. C1110450 • Use holder, BMW No. 11 7 521, and install nut. Tightening torques: C1110460 Clutch drum ..........60 Nm • Check threads and tooth profiles for damage and Disassembling and assembling distortion.

  • Page 116: Checking Individual Components Of Driving Variator

    • Check friction faces of both side plates for wear Checking rollers and damage. C1110480 C1110500 • Check with a precision straightedge and feeler Wear value: gauge. Dia. at flattest point ....min. 19.6 mm (0.77 in) • Check inside diameter of inner plate. Wear values: Smoothness of friction face...

  • Page 117: Checking Shoes And Spring Clips For Wear

    Checking shoes and spring clips for wear Assembling: C1110520 C1110490 • • Mount shoes and spring clips on driver. Uniformly coat tracks of primary inner plate with • Position driver on inner plate. approx. 20 g (0.71 oz.) of grease and install roll- •...

  • Page 118: Checking Individual Components Of Driven Variator

    Note: Replace the clutch if the springs are damaged or if the weights are not uniformly positioned. 00 2 510 C1110530 • Check radial runout on variator shaft with dial gauge and dial-gauge holder, BMW No. 00 2 500. 11.40...

  • Page 119: Disassembling Driven Variator

    Working from the inside, press out guide pin (1) and guide sleeve (2). • Remove outer plate (3). C1110560 • Engage hooks of retainer, BMW No. 11 7 641, in bottom plate of pulley. • Release nut with specially ground socket, BMW No. 11 7 643. 11.41...

  • Page 120: Checking Individual Components

    C1110590 • Remove O-rings (1) and check for damage. • Check both shaft sealing rings (2) for damage and correct seating. Checking individual components • Length of spring at outer plate. • Outside diameter “D” of sleeve in inner plate. C110600 •...

  • Page 121: Checking Bearing

    • Visually and manually check inner grooved ball • bearing (2) and needle bearing (4) of inner belt Using support ring, BMW No. 36 6 610, and pulley plate (1). puller, BMW No. 00 8 570, remove needle bear- •...
  • Page 122 Place grooved ball bearing (2) in position with Press in needle bearing (4) with special assembly open side toward needle bearing and using a tool, BMW No. 11 7 642, and a manual press. • manual press and tubular drift, Check inside diameter of secondary outer plate BMW No.

  • Page 123: Assembling Driven Variator

    • Position spring on pin (arrow) of guide bow. • Engage clutch at end of spring. • Using guide, BMW No. 11 7 644, position outer plate on inner plate. • Coat guide sleeves and guide pin with grease Caution: and insert into 3 recesses in secondary outer Assembly is spring-loaded - risk of injury.

  • Page 124: Replacing Shaft Sealing Ring For Variator Shaft In Gearbox Cover (Shaft Installed)

    Deburr seat for shaft sealing ring and remove metal chippings. • Install shaft sealing ring with tubular drift, BMW No. 11 7 571. Operating fluids: Shaft seats ......Klüber paste 46 MR 401 Seats of shaft sealing rings .........Klüber paste 46 MR 401 Hypoid oil, API GL4 ........95 ccl (Imp.pint/US quart)

  • Page 125: Disassembling And Assembling Gearbox, Checking Individual Components

    C1110680 Disassembling and # Removing gearbox cover 23 00 043 11 11 018 assembling gearbox, checking – Remove complete variator assembly. individual components – Drain gearbox oil Jobs marked # can also be performed with the drive swinging arm installed. Clean the individual components and check the following parts for wear: •...

  • Page 126: Removing Gearbox Shafts

    When installing: C1110700 C1110720 • Remove securing screws. • Install two M6x70 screws in tapped bores (ar- Note: rows) and pull off cover. Grease one side of a thrust washer for intermediate • Use screwdriver to pry out shaft sealing ring. shaft and affix it to flat of large gear.

  • Page 127: Replacing Sealing Ring Of Output Shaft In Housing

    • Install dry shaft sealing ring until flush with flat of When installing: housing, using mandrel, BMW No. 11 7 581. Caution: Make sure that shaft sealing ring does not contact 11 7 592 grooved ball bearing - check clearance.

  • Page 128: Replacing Grooved Ball Bearing For Variator Shaft In Cover

    • Working from outside and using mandrel, • BMW No. 11 7 571 D = 32 mm (1.260 in) or To avoid risk of breakage, support housing by 24 mm socket , press grooved ball bearing into placing tubular spacer, BMW No. 31 5 652, gearcase cavity.

  • Page 129: Replacing Grooved Ball Bearing For Variator Shaft In Housing

    • Remove grooved ball bearing with • puller, BMW No. 11 7 550. Lightly oil outside circumference of grooved ball bearing and press into housing with mandrel, D = 40 mm (1.575 in) h = 170 mm (6.693 in) or 30 mm socket, until seated.

  • Page 130: Replacing Grooved Ball Bearing For Output Shaft In Cover

    C1110810 BMW No. 11 7 550. • To avoid risk of breakage, support housing by placing tubular spacer, BMW No. 31 5 652, underneath bearing seat. • Lightly oil outside circumference of grooved ball bearing and press into cover with mandrel, D = 40 mm (1.575 in) or 30 mm socket, until...

  • Page 131: Replacing Grooved Ball Bearing For Output Shaft In Housing

    Working from outside and using mandrel, bearing and press into housing with mandrel, BMW No. 11 7 571 D = 42 mm (1.575 in) or D = 50 mm (1.969 in) h = 200 mm (7.874 in) or 24 mm socket, press bearing into gearcase 36 mm socket, until seated.

  • Page 132: Measuring Gearbox Shafts

    Measuring gearbox shafts Testing and measuring output shaft # Testing and measuring variator shaft C1110860 C1110840 1 Measure between tips Permissible runout .... max. 0.06 mm (0.002 in) 1 Measure between tips 2 Bearing journal, gearbox cover, grooved ball Permissible runout ....max. 0.05 mm (0.002 in) bearing 2 Bearing, gearbox cover, grooved ball bearing dia........min.

  • Page 133: Removing Shaft Sealing Ring For Crankshaft

    – Separate halves of housing. C1110880 • Using special assembly tool, BMW No. 11 7 591, install shaft sealing ring with sealing lip facing toward inside. C1110870 • Use screwdriver with rest for leverage to pry out shaft sealing ring.

  • Page 134: Cylinder Head

    C1110890 ring. • Use depth gauge to measure distance “A”. • Use special socket, BMW No. 11 7 020, to re- move double temperature sensor. Wear value: Distance A ......max. 6 mm (0.236 in) Tightening torques: Double temperature sensor ......15 Nm Note: If distance “A”...

  • Page 135: Replacing Chain Tensioner

    Install liberally oiled chain tensioner with flat to- • ward chain. Slacken clamp (arrow) with pliers, • Turn engine through at least one full revolution. BMW Nr. 17 5 500 securing breather hose. • • Check valve clearances. Disconnect hose. •...

  • Page 136: Removing Camshaft Gears

    Replacing chain guides Removing camshaft gears Replacing guide rail • Secure crankshaft at TDC. 11 31 112 Replacing guide rail – Cylinder head cover removed. – Chain tensioner removed. C1110930 • Remove securing screws. C1110940 • Remove guide rail. • Lift guide rail up to remove.

  • Page 137: Removing And Installing Or Replacing Timing Chain

    11 31 051 Removing and installing or replacing # Replacing cylinder head timing chain – Removing oil pump. C1110970 C1110960 • Work with drive swinging arm installed: – Remove the silencer system. • Use a coloured marker to mark outside of chain. –...

  • Page 138: Removing Cylinder

    C1110980 • Raise cylinder clear of piston. • Tighten collar nuts in diagonally opposite se- quence, using socket insert, BMW No. 11 7 541. Checking cylinder dimensions Wear values: Tightening torque: Measuring planes: Collar nut ..........30 ±1 Nm 1 90°...

  • Page 139: Replacing Stud Bolts

    Stud bolt ............10 Nm 11 7 632 C1111000 • Secure crankshaft at TDC. • Use sliding sleeve for pistons, BMW No. 11 7 632. C1111010 Note: Do not damage the piston. • Carefully slip sleeve up and to one side to re- move.

  • Page 140: Removing And Installing Or Replacing Piston

    Micro-chamfer......0.1 mm (0.004 in) Taper-face oil-control ring ... 0.1 mm (0.004 in) C1111030 When installing: • • Remove piston pin with drift, BMW No. 11 7 631. Install with “Top” uppermost. • Turn rings so that gaps are uniformly spaced. When installing: •...

  • Page 141: Checking Piston Dimensions

    Removing crankshaft Checking piston dimensions – Remove cylinder. – Remove starter motor. – Remove cylinder. – Remove cylinder base gasket. – Secure engine in assembly stand. – Variator side up. C1111060 • Measure piston diameter 8 mm (0.31 in) above bottom edge of piston skirt.

  • Page 142: Measuring Axial Play

    Measuring housing Measuring axial play – Remove crankshaft General instructions Room temperature ....20-25 °C (68-77 °F) Cleaners • Make sure that lube-oil bores are unobstructed • Check seats of grooved ball bearings All grooved ball bearings: Press-fit interference ..min. 0.01 mm (0.0004 in) Measuring main bearings C1111090 •...

  • Page 143: Replacing Bearing Shells

    • Support bearing seat with tubular spacer, D = 36 mm (1.417 in) H = 30 mm (1.181 in). • Using mandrel, BMW No. 11 7 622, and working C1111110 from the outside, press in the bearing shells, until seated.

  • Page 144: Replacing Cylindrical Pin For Starter Double Gear

    Replacing cylindrical pin for starter double gear Installing crankshaft C1111140 C1111150 Wear value: Cylindrical pin dia..... 9.95 mm (0.392 in) Caution: • Heat surrounding zone to approx. 100° C Check axial play if crankshaft or crankcase has been (212 °F) and use visegrips to remove cylindrical replaced.

  • Page 145: Joining Halves Of Crankcase

    Joining halves of crankcase Caution: Make sure that all bearings of crankshaft are ade- quately lubricated. C1111170 • Add the two measured values and the thickness of the gasket (when compressed), 0.45 mm (0.018 in). • Check installed length of crankshaft. •...
  • Page 146 11.68...
  • Page 147 12 Engine electrics Contents Page Technical Data ..........................3 Replacing spark plug/ignition lead ..................5 Replacing spark plug ........................5 Replacing ignition lead .........................6 Replacing ignition coil .......................6 BMW engine management system (BMW-Motor-Steuerung, BMS) ....7 Replacing BMS control unit .......................7 Replacing starter motor ......................7 12.1...
  • Page 148 12.2...

  • Page 149: Technical Data

    Technical Data Starter motor Type Permanent-magnet motor Power rating kW 0.6 Spark plug NGK CR 8E Thread metric M 10 x 1 Ignition Ignition system BMW engine management system (BMW-Motor- Steuerung, BMS) 12.3...
  • Page 150 12.4...

  • Page 151: Replacing Spark Plug/Ignition Lead

    – Remove left service cover.............See Group 46 C1120030 • Use spark-plug wrench, BMW No. 12 3 531, to remove spark plug. When installing: • Installation is the reverse of the removal proce- dure: pay particular attention to the following.

  • Page 152: Replacing Ignition Lead

    Replacing ignition lead Replacing ignition coil 12 12 085 12 13 000 – Remove rear left side panel.............See Group 46 Caution: Switch off ignition; disconnect earth (ground) lead from battery and insulate it. – Remove rear left side panel.............See Group 46 C1120010 •...

  • Page 153: Bmw Engine Management System (Bmw-Motor-Steuerung, Bms)

    BMW engine management system Replacing starter motor 12 41 020 (BMW-Motor-Steuerung, BMS) Replacing BMS control unit 13 61 025 – Open the seat. Caution: – Remove the backrest. Disconnect ground lead from battery and insulate. – Remove the rear stowage compartment.
  • Page 154 12.8...
  • Page 155 13 Fuel preparation and control Contents Page Removing and installing air filter housing ..............3 Removing and installing intake air silencer ..............3 Removing and installing throttle-valve stub pipe ............5 13.1...
  • Page 156 13.2...
  • Page 157 Removing and installing air Removing and installing 13 72 110 13 72 128 filter housing intake air silencer – Remove air filter housing. C1130010 C1130090 • Release the fasteners (arrows). • Release the fastener (arrow). C1130100 C1130040 • Slacken off the hose clip (arrow) at the intake air •...
  • Page 158 17 5 500 C1130030 C1130050 • • Disconnect plug (3). Slightly raise the BMW C1 with lifter (arrow), • Open hose clamp (2) with pliers, BMW No. 00 1 570. • BMW No. 17 5 500. Remove the fasteners securing the spring struts •...
  • Page 159 Disengage throttle cable from holder and cam disc. C1130080 • Open hose clamp (arrow) securing intake hose with pliers, BMW No. 17 5 500 • Pull the throttle valve complete up and to the rear while easing it out of the intake hose. •...
  • Page 160 13.6...
  • Page 161 16 Fuel tank and lines Contents Page Technical Data ..........................3 Removing and installing fuel tank ..................5 Replacing fuel filter ........................7 Fuel pump unit ..........................8 Removing the fuel pump unit .....................8 Replacing intake filter ........................9 Removing and installing fuel pump ..................9 Installing fuel-pump unit ......................
  • Page 162 16.2...

  • Page 163: Technical Data

    Technical Data Tank capacity l (Imp. 9 (1.98/2.38) pint/US quart) Including reserve of l (Imp. 2.5 (3.52/2.11) pint/US quart) Type of fuel Super (premium), unleaded 95 octane (RON) Fuel pump Type Peripheral-gear pump Rated voltage V 12 Operating voltage V 7 - 14 Fuel pressure bar (psi) 2.5 (35.57) operating pressure 3.8 (54.07) max...
  • Page 164 16.4...

  • Page 165: Removing And Installing Fuel Tank

    Release tunnel panel on right from front anchor- age point. C1160010 • Warning: Use hose clamps, BMW No. 13 3 010, to close Comply with safety precautions when handling or off fuel hoses (arrows). • working with fuel; note that the fuel lines are pressu- Open hose clamps with rised.
  • Page 166 C1160040 • Position the vehicle with • Cut through cable tie (arrow) of connecting cable lifter, BMW No. 00 1 570, and for stand switch. adapter BMW No. 00 1 580. • Open cable tie (arrow). Additional work: vehicles with ABS: –...

  • Page 167: Replacing Fuel Filter

    C1160090 Tightening torques: • Fuel tank holder to frame........ 9 Nm Use hose clamps, BMW No. 13 3 010, to close Holder for washing-fluid reservoir/ABS control unit off fuel hoses (arrows). • to frame............9 Nm Open hose clamp (1) with pliers, BMW No.

  • Page 168: Fuel Pump Unit

    – Remove top tunnel panel.............See Group 46 C1160010 • Use hose clamps, BMW No. 13 3 010, to close off fuel hoses (arrows). • Slacken hose clamps with pliers, BMW No. 17 5 500. • Pull fuel lines out of holder (1).

  • Page 169: Replacing Intake Filter

    Replacing intake filter Removing and installing fuel 16 12 002 16 12 000 pump C1160110 C1160120 • Remove circlip (3). • • Remove intake filter (1); pry it clear of its seat if Disconnect connecting cable (2) from fuel necessary. pump (3).

  • Page 170: Installing Fuel-Pump Unit

    Installation is the reverse of the removal proce- dure: pay particular attention to the following. C1160100 • Tighten union nut (arrow) using wrench, BMW No. 16 1 721. Tightening torques: Union nut ............. 20 Nm C1160140 • Install float (3) in arm (4).
  • Page 171 17 Radiator Contents Page Technical Data ..........................3 Coolant circuit ..........................5 Removing and installing coolant hoses ................7 Opening hose clamps ........................7 Closing hose clamps ........................7 Replacing feed hoses to radiator .....................7 Hose between radiator and elbow .......................7 Hose between elbow and coolant pipe ....................7 Hose between elbow and bowl ......................8 Vent hose ............................8 Replacing return hose to radiator...
  • Page 172 Contents Page Changing coolant ........................14 Draining coolant ..........................14 Draining coolant from feed line/engine ....................14 Draining coolant from return line ......................15 Draining coolant from expansion tank ....................15 Adding coolant ..........................15 Adding coolant to feed and return lines and engine ................15 Filling expansion tank with coolant ....................

  • Page 173: Technical Data

    Technical Data Cooling-system capacity Total capacity l (Imp. 1.4 (2.464/1.479) pint/US quart) Coolant circuit l (Imp. 1.2 (2.11/1.27) top-up capacity pint/US approx. 1.2 l (2.11/1.27) quart) Expansion tank l (Imp. 0.2 (0.35/0.21) pint/US quart) Coolant Use only nitride-free long-life antifreeze agents and corrosion inhibitors Mixing ratio 50% antifreeze...
  • Page 174 17.4...

  • Page 175: Coolant Circuit

    Coolant circuit C1179010 17.5...
  • Page 176 17.6...

  • Page 177: Removing And Installing Coolant Hoses

    17 12 150 Hose between radiator and elbow 17 5 500 C1170000 • Open all hose clamps with pliers, 17 5 500 BMW No. 17 5 500. C1170020 Closing hose clamps • Remove coolant hose (arrow). 17 12 154 Hose between elbow and coolant pipe...

  • Page 178: Vent Hose

    Replacing return hose to 17 12 159 Hose between elbow and bowl 17 12 175 radiator – Remove front fairing panel. – Remove left side trim panel.............See Group 46 – Drain coolant. 17 12 180 Hose between radiator and coolant pipe 17 5 500 C1170040...

  • Page 179: Replacing Coolant Hoses On Engine

    C1170070 Replacing coolant hoses on engine 11 53 120 Replacing thermostat – Remove engine coolant hoses. • – Open the seat. Remove thermostat (4). – Remove left service cover.............See Group 46 Installing engine coolant hoses • – Drain coolant. Installation is the reverse of the removal proce- dure.

  • Page 180: Removing And Installing Coolant Pipes

    Pull coolant pipe (1) forward to remove. C1170080 • Remove fasteners (arrows) from frame on the right. • Open hose clamps (1) with pliers, BMW No. 17 5 500. 17 5 500 C1170090 • Remove fasteners (arrows) from frame on the left. •...

  • Page 181: Installing Coolant Pipes

    C1170110 • Remove fastener (arrows) from front frame. • Open hose clamps (1) with pliers, BMW No. 17 5 500. 17 5 500 C1170090 • Remove fasteners (arrows) from frame. • Open hose clamps (1) with pliers, BMW No.

  • Page 182: Replacing Vapour Discharge Hose

    If the expansion tank still contains coolant: • Bend back the vapour discharge hose to close it hose off or shut it off with clamp, BMW No. 13 3 010. • Pull the vapour discharge hose out toward the –...
  • Page 183 Removing and installing 17 11 087 When installing: • Installation is the reverse of the removal proce- expansion tank dure. • Fill system with coolant. • – Open the seat. After running the engine check the coolant level – Remove the backrest. and top up if necessary.

  • Page 184: Changing Coolant

    Changing coolant 17 00 035 Draining coolant from feed line/engine Note: Change the coolant at least every 2 years Draining coolant – Remove front fairing panel. – Swing the headlight forward and down. – Open the seat.............See Group 46 C1170160 •...

  • Page 185: Draining Coolant From Return Line

    Remove moulded hose (4) for return from Tighten vent screw in engine. holder (3). • Open hose clamps (1) with pliers, BMW No. 17 5 500. • Disconnect moulded hose (4) from coolant pipe. When installing: • Installation is the reverse of the removal proce- dure.

  • Page 186: Filling Expansion Tank With Coolant

    C1170190 • Remove fasteners at filler bowl. • Secure pump, BMW No. 17 0 500, with adapter, BMW No. 17 5 520, and spring clip, BMW No. 17 5 525 to filler bowl. • Pressure-test the system; the pressure must re- main unchanged for at least 5 minutes.

  • Page 187: Removing And Installing Radiator With Fan

    • Disconnect plug (1) for fan motor. • Disconnect plug (2) for horn. • Open hose clamp (arrow) on right with pliers, BMW No. 17 5 500. C1170200 17 5 500 • Disconnect plug (1) from headlight. • Remove parking light (2) from its socket.

  • Page 188: Removing And Installing Radiator With Fan Shroud In Front Frame

    – Remove front frame with radiator. C1170220 • Open hose clamp (arrow) on vapour discharge hose with pliers, BMW No. 17 5 500. C1170240 • Disconnect vapour discharge hose (1). • Remove fasteners (1) securing air duct.

  • Page 189: Replacing Radiator

    Replacing radiator Replacing air duct 17 11 029 17 11 034 – Remove radiator with fan shroud. – Remove radiator with fan shroud. C1170260 C1170280 • • Release the fasteners (arrows). Release the fasteners (arrows). • • Pull fan shroud to the rear and down to remove. Remove air duct.

  • Page 190: Replacing Filler Bowl

    Fasteners for filler bowl ......... 9 Nm C1170290 • Remove fasteners (2, 3) from filler bowl. • Open hose clamps (arrows) with pliers, BMW No. 17 5 500. • Pull filler bowl to one side. • Disconnect vapour discharge hose (1) from filler bowl.
  • Page 191 18 Exhaust system Contents Page Technical Data ..........................3 Removing and installing silencer heat shield ...............5 Removing and installing silencer system ................5 Removing and installing oxygen sensor ................7 18.1...
  • Page 192 18.2...
  • Page 193 Technical Data Silencer system Exhaust-emission control 3-way catalytic converter Silencer (muffler) Reflection/absorption silencer made of rustproof stainless steel 18.3...
  • Page 194 18.4...
  • Page 195 Removing and installing Removing and installing 18 12 212 18 00 020 silencer heat shield silencer system C1180000 C1180020 • • Remove 4 fasteners (arrows). Open cable clip (arrow). • • Remove exhaust heat shield. Disconnect plug (1) for the oxygen sensor. When installing: •...
  • Page 196 When installing: • Installation is the reverse of the removal proce- dure: pay particular attention to the following. Caution: When installing, make sure that the oxygen sensor cable is correctly routed and secured. Note: When installing, use a new gasket at the cylinder head.
  • Page 197 Tightening torque: Oxygen sensor ..........23 Nm 11 7 020 C1180060 • Slacken the oxygen sensor with socket wrench insert, BMW No. 11 7 020, (arrow). • Remove socket wrench insert. • Remove the oxygen sensor by hand. Caution: When removing the oxygen sensor, take care not to damage the cable on the exhaust heat shield.
  • Page 198 18.8...
  • Page 199 31 Front forks Contents Page Technical Data ..........................3 Removing and installing telescopic forks and fork bridge ........5 Removing telescopic fork ......................5 Removing and installing fixed tube ..................6 Removing fork bridge .........................7 Fork bridge components ......................8 Disassembling fork bridge ......................8 Removing pot-type joints ........................8 Installing pot-type joints ........................9 Removing ball bearing with stud ......................9 Installing ball bearing and stud ......................
  • Page 200 31.2...
  • Page 201 Fixed tube extl. dia. mm (in) 32 (1.26) Maximum permissible fixed fork tube runout mm (in) 0.1 (0.004) Telescopic-fork oil Telescopic fork oil - approved grades BMW telescopic fork oil Capacity per fork leg l (Imp. 0.320 (0.56/0.34) pint/US quart)
  • Page 202 31.4...

  • Page 203: Removing And Installing Telescopic Forks And Fork Bridge

    Remove ABS sensor (1). 00 1 570 C1310000 C1310020 • Raise the vehicle with lifter, BMW No. 00 1 570. – Lower the front wheel (move the large lever of the • parking mechanism down). Remove fastener (arrow) securing brake hose/ –...
  • Page 204 31 5 603 C1310040 • Using a cranked ring wrench, a/f 21, and hexa- gon socket wrench, BMW No. 31 5 603, release fastener (arrow) securing leading link to fork bridge. • Pull the telescopic forks down to remove.

  • Page 205: Removing Fork Bridge

    Removing fork bridge 31 42 028 Caution: The fastener is secured with thread-locking com- pound; heat if necessary, but take care not to over- heat lines and cables. Caution: Protect painted parts from scratching: apply adhe- sive masking tape if necessary. C1310060 •...

  • Page 206: Fork Bridge Components

    C1310070 Fork bridge components Disassembling fork bridge 31 42 528 1 Stuffing ring of pot-type joint bearing 2 Wiper sleeve of pot-type joint bearing 3 Pot-type joint bearing Removing pot-type joints 4 Fork bridge 5 Lock ring 6 Bearing of fork bridge 7 Spacing sleeve 8 Stud C1310080...

  • Page 207: Installing Pot-Type Joints

    31 5 661 C1310090 C1310110 • Press out pot-type joint (3) with wiper sleeve (9) using mandrel, BMW No. 31 5 661, and bush- ing, BMW No. 31 5 662. Note: Take care not to damage threads (arrow). Installing pot-type joints •...

  • Page 208: Installing Ball Bearing And Stud

    31 6 533 31 6 531 C1310150 • Install spacer (7) complete with threaded stud (8) in fork bridge, using mandrel, BMW No. 31 6 532 and sleeve, BMW No. 31 6 533 • Install lock ring (5). C1310130 •...

  • Page 209: Installing Telescopic Fork

    0.34 US quarts)/slider tube C1310000 • Tightening torques: Raise the vehicle with lifter, BMW No. 00 1 570. • Leading link to fork slider bridge Lower the front wheel (move the large lever of the ( + Loctite 243) ........... 127 Nm parking mechanism down).
  • Page 210 • Remove ABS sensor (1). C1310040 • Using a cranked ring wrench, a/f 21, and hexa- gon socket wrench, BMW No. 31 5 603, release fastener (arrow) securing leading link to fork bridge. Note: Note that telescopic-fork oil can escape.

  • Page 211: Replacing Sliding-Tube Seal

    Do not scrape the slider tube – mask it off if neces- 31 3 631 sary. C1310170 • Drive in the new sealing ring with drift, BMW No. 31 3 631, until seated. • Install slider tube bridge complete with slider tubes and front wheel. Replacing ball joint 31 42 055 C1310160 •...

  • Page 212: Installing Slider Tube Bridge With Slider Tubes

    Place both ends of fixed tube in V-blocks. • Turn fixed fork tube slowly and measure it with a Caution: dial gauge, BMW No. 00 2 510. Take care not to damage the seals on the slider tubes. Caution: •...

  • Page 213: Removing Leading Link

    00 1 570 C1310040 C1310000 • Detach the leading link from the slider tube bridge. • Raise the vehicle with lifter, BMW No. 00 1 570. • Lower the front wheel (move the large lever of the parking mechanism down). 31.15...

  • Page 214: Replacing Left And Right Angular-Contact Ball Bearings For Leading Link

    Slacken fasteners (3-5) securing leading-link Pull out bearing (6) with link shaft (8), right, using shaft. M 10 threaded rod (D), BMW No. 31 5 701, M 10 • Remove fasteners (1, 7) securing leading-link nut (C) with rest, BMW No. 31 5 702, puller (B), shaft.

  • Page 215: Installing Leading Link

    Place link shaft with angular-contact ball bearing, right, in position and install using M 10 threaded rod (D), BMW No. 31 5 701, M 10 nut (B) with rest, BMW No. 31 5 702, installation bush (C), BMW No. 31 5 706, and puller (A), BMW No.
  • Page 216 31.18...
  • Page 217 32 Steering Contents Page Technical Data ..........................3 General view of handlebar .......................5 Removing and installing handlebar fittings ..............6 Removing and installing left handlebar fitting ..............6 Removing and installing right handlebar fitting ..............7 Removing and installing left and right handlebar levers ........8 Removing and installing left/right brake fittings ............9...
  • Page 218 32.2...
  • Page 219 Technical Data Type One-part tubular handlebar Handlebar tube diameter mm (in) 22 (0.866) Steering lock angle ° 38 Width of handlebar mm (in) 650 (25.59) 32.3...
  • Page 220 32.4...
  • Page 221 General view of handlebar C1329010 32.5...
  • Page 222 Removing and installing handlebar When installing: • Installation is the reverse of the removal proce- fittings dure: pay particular attention to the following. Removing and installing left 32 72 053 handlebar fitting Caution: Make sure that lines and cables are correctly routed. –...
  • Page 223 Removing and installing right 32 72 110 handlebar fitting – Remove handlebar trim. – Remove instrument panel.............See Group 46 C1320050 • Remove Bowden cable (arrow) from the front section of the handlebar fitting. C1320030 • Disconnect plug (1). • Open cable clip (3).
  • Page 224 Removing and installing When installing: 32 72 072/074 • Installation is the reverse of the removal proce- left and right handlebar levers dure: pay particular attention to the following. Caution: Make sure that all lines and the Bowden cable are correctly routed.
  • Page 225 Removing and installing 32 72 118/120 When installing: • Installation is the reverse of the removal proce- left/right brake fittings dure: pay particular attention to the following. The procedure for removing and installing the left brake fitting is described below. The procedure for Warning: removing and installing the right brake fitting is ana- Make sure that the gap at the clamp is of uniform...
  • Page 226 Removing and installing 32 71 008 handlebar – Remove handlebar trim. – Remove instrument panel.............See Group 46 – Remove seat-belt central release mechanism.............See Group 72 • Slacken clamping screws for brake fittings. • Remove brake fittings from handlebar. C1320100 •...
  • Page 227 Replacing throttle cable When installing: 32 72 305 • Installation is the reverse of the removal proce- dure: pay particular attention to the following. – Remove handlebar trim. – Remove instrument panel. Warning: – Open the seat. Make sure that the gaps at the clamps for the brake ............
  • Page 228 32.12...

  • Page 229: Rear Wheel Drive

    33 Rear wheel drive Contents Page Technical Data ..........................3 Removing and installing left/right spring strut ............5 Replacing spring/shock absorber ..................6 33.1...
  • Page 230 33.2...
  • Page 231 Technical Data Rear suspension Spring strut Coil spring with single-tube gas-filled shock ab- sorber Suspension travel mm (in) 85 (3.35) at wheel mm (in) 100 (3.94) at spring strut 33.3...
  • Page 232 33.4...
  • Page 233 C1130050 Tightening torques: Top fastener for spring strut ......41 Nm • Slightly raise the BMW C1 with lifter (arrow), Bottom fastener for spring strut....21 Nm BMW No. 00 1 570. C1330030 • Remove fastener (arrow) securing spring strut to frame.
  • Page 234 33 5 652 33 5 600 C1330040 • Compress spring with compressor (3), BMW No. 33 5 600, adapter (2) BMW No. 33 5 652, and adapter (1) BMW No. 33 5 606. C1330010 • Remove retaining plate (arrow). •...
  • Page 235 34 Brakes Contents Page Technical Data ..........................3 Front brake calliper ........................5 Removing and installing brake calliper ..................5 Rear brake calliper ........................6 Removing and installing rear brake calliper .................6 Removing and installing front brake disc ...............8 Removing and installing rear brake disc .................9 Removing and installing front ABS sensor ..............9...
  • Page 236 Contents Page Installing front brake lines/hoses – with ABS ..............19 Removing and installing rear brake lines/hoses ............19 Brake hose between left brake handlebar fitting and brake line ......19 Brake line between brake hose, left brake lever fitting, and brake hose to brake calliper - without ABS .........................21 Brake lines between brake hose, left brake lever fitting, and brake hose to brake...

  • Page 237: Technical Data

    Technical Data Brake fluid DOT 4 Brake actuation Hydraulic Front wheel Front brake 2-piston floating calliper with fixed brake disc Brake disc diameter fixed mm (in) 220 (8.66) Brake-disc thickness mm (in) 4.5 (0.17) Minimum thickness mm (in) 4.0 (0.15) Permissible lateral runout mm (in) 0,25 (0.010) Brake pad surface area...
  • Page 238 34.4...

  • Page 239: Front Brake Calliper

    Caution: Do not damage the brake pads when installing. • If necessary, press the brake pads/pistons fully back with resetting tool, BMW No. 34 1 500. • Fit new sealing rings on banjo bolt (1). – Fill and bleed the brake system.

  • Page 240: Rear Brake Calliper

    – Remove silencer system.............See Group 18 • Raise the BMW C1 on lifter (arrow), BMW No. 00 1 570, until rear wheel is clear of the ground, making sure that the BMW C1 is se- cure. C1340010 • Remove hexagon nut (4) of drive shaft.
  • Page 241 C1340020 C1340030 • • Use a crowbar to press the brake calliper in the Slacken banjo bolt (1) for brake hose and remove direction indicated by the arrow against the brake hose. • brake disc to force back the brake pads and pis- Pull rear wheel with spacer (3) and brake-calliper ton.
  • Page 242 Caution: Do not damage the brake pads when installing. • If necessary, press the brake pads/pistons fully back with resetting tool, BMW No. 34 1 500. • Fit new sealing rings on banjo bolt for brake hose. – Fill and bleed the brake system.

  • Page 243: Brake Disc

    Removing and installing rear Removing and installing 34 21 301 34 52 044 brake disc front ABS sensor – Remove rear wheel. – Remove front fairing panel.............See Group 36 – Swing the headlight forward and down.............See Group 46 Caution: Disconnect ground lead from battery and insulate.
  • Page 244 When installing: • Installation is the reverse of the removal proce- dure: pay particular attention to the following. Caution: Install the ABS sensor wire carefully and secure it with cable ties. Caution: When installing a new ABS sensor, check the clear- ance of the ABS sensor.
  • Page 245 Replacing front ABS sensor Removing and installing rear 34 51 100 34 52 111 ring ABS sensor – Remove front wheel.............See Group 36 Caution: Disconnect ground lead from battery and insulate. – Open the seat.............See Group 46 C1340050 •...
  • Page 246 Replacing rear ABS sensor 34 51 109 ring – Remove rear wheel ............See Group 36 C1340120 • Open cable tie for ABS sensor cable (arrow). • Remove fastener (1) for ABS sensor. When installing: C1340060 • Installation is the reverse of the removal proce- dure: pay particular attention to the following.

  • Page 247: Checking And Adjusting Speed/Abs Sensor Gap If Necessary

    Checking and adjusting speed/ABS Rear wheel 36 30 020 sensor gap if necessary Front wheel 36 30 300 Caution: Check the ABS sensor gap if the ABS sensor, sen- sor ring, brake-calliper carrier, bearing of brake-cal- Caution: liper carrier or spacer bushing for drive shaft have Check the speed/ABS sensor gap if the speed/ABS been replaced.

  • Page 248: Control Unit

    Removing and installing ABS 34 51 050 control unit Warning: All work on the ABS control unit must be carried out by an authorised BMW workshop. Caution: Disconnect the negative battery cable first, then dis- connect the positive cable. C1340150 –...
  • Page 249 Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid de- stroys paint. Wrap clean cloths around open pres- sure lines to prevent residual brake fluid from escaping. • Disconnect brake lines from ABS control unit. C1160040 •...
  • Page 250 When installing: • Installation is the reverse of the removal proce- dure: pay particular attention to the following. C1340210 • Install the brake lines in the following sequence: 2, 1, 3, 4. C1340150 • Connect plug (1) to ABS control unit by first opening latch (arrow) of plug, positioning the plug on the ABS control unit, pushing it to the left and pressing slightly down until the latch engag-...

  • Page 251: Removing And Installing Front Brake Lines/Hoses

    C1340220 Removing and installing front brake When installing: • Installation is the reverse of the removal proce- lines/hoses dure: pay particular attention to the following. – Remove handlebar trim. – Remove instrument panel. Caution: – Remove knee pad. Make sure that all lines and the Bowden cables are ............See Group 46 correctly routed and that cables cannot chaff.

  • Page 252: Removing Front Brake Lines/Hoses - With Abs

    C1340230 Removing front brake lines/hoses – Brake line between brake hose, front wheel and ABS control unit with ABS – Remove top and left tunnel panels.............See Group 46 • Brake hose between front wheel and brake line, Remove brake line (7) from holders (4 - 6). •...

  • Page 253: Removing And Installing Rear Brake Lines/Hoses

    Brake hose between right brake handlebar fit- ting and brake line, ABS control unit Tightening torques: Fastener, brake hose to slider tube bridge ........... 5 Nm Interface, brake hose/brake line ....18 Nm Brake hose to brake lever fitting ....18 Nm Banjo bolt to brake calliper......
  • Page 254 When installing: • Installation is the reverse of the removal proce- dure: pay particular attention to the following. Caution: Make sure that all lines and the Bowden cables are correctly routed and that cables cannot chaff. – Fill and bleed the brake system. Tightening torques: Interface, brake hose/brake line ....

  • Page 255: Brake Line Between Brake Hose, Left Brake Lever Fitting, And Brake Hose To Brake Calliper - Without Abs

    C1340280 Brake line between brake hose, left When installing: • Installation is the reverse of the removal proce- brake lever fitting, and brake hose to dure: pay particular attention to the following. brake calliper - without ABS – Remove instrument panel. Caution: –...

  • Page 256: Brake Lines Between Brake Hose, Left Brake Lever Fitting, And Brake Hose To Brake Calliper - With Abs

    Brake lines between brake hose, left brake lever fitting, and brake hose to brake calliper - with ABS Brake lines between brake hose, brake handle- bar fitting and ABS control unit – Remove instrument panel. – Remove knee pad. – Remove top, left and right tunnel panels.
  • Page 257 When installing: Brake lines between ABS control unit and brake • Installation is the reverse of the removal proce- hose to brake calliper dure: pay particular attention to the following. – Remove right service cover. – Remove top, left and right tunnel panels.............See Group 46 Caution: –...
  • Page 258 When installing: • Installation is the reverse of the removal proce- dure: pay particular attention to the following. Caution: Make sure that all lines and the Bowden cables and vapour discharge line are correctly routed. Make sure the hoses do not chaff. C1340310 •...

  • Page 259: Brake Hose Between Brake Line And Brake Calliper

    C1340330 Brake hose between brake line and When installing: • Installation is the reverse of the removal proce- brake calliper dure: pay particular attention to the following. – Remove right service cover.............See Group 46 – Drain the rear brake system. Caution: Make sure that lines and cables are correctly routed.

  • Page 260: Checking Brake Pads And Discs For Wear/Replacing

    Checking brake pads and discs for Rear brake pads wear/replacing Checking brake pads for wear Warning: Brake pad thickness must not fall below the mini- mum value. Always replace pads as a complete set. 34 11 008 Front brake pads C1340360 •...

  • Page 261: Replacing Brake Pads

    If the brake pads/pistons cannot be forced back in this way, there may be some other fault in the brake • system. Remove retaining pin (1) using drift or pliers, BMW No. 34 1 541. • Remove the brake pads. When installing: •...

  • Page 262: Rear Brake

    Remove fastener (1) from bottom of spring strut and tie the spring strut up out of the way. • Remove retaining pin (2) using pliers, BMW No. 34 1 541. • Caution: Lift out the brake pads toward the rear.

  • Page 263: Checking The Brake Discs

    Checking the brake discs • Turn the handlebars to full left-hand lock. • Carefully check the brake discs for cracking, damage, deformation and scoring. Note: The volume of the brake fluid (MIN/MAX) is sufficient for lining thicknesses from new to the wear limit. It is not normally necessary to top up the fluid to accom- modate lining wear.

  • Page 264: Checking Fluid Level At The Open Brake Fluid Reservoir

    Checking fluid level at the open brake fluid reservoir The procedure for checking the level in the left brake fluid reservoir is described below. The procedure for checking the level in the right brake fluid reservoir is analogous. Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle as brake fluid de- stroys paint.

  • Page 265: Front Brake

    Changing brake fluid and 34 00 034 Bleeding front brake circuit – Add brake fluid up to the top of the sight glass. bleeding brake system • Connect the brake bleeding device to the bleed screw on the brake calliper. •...

  • Page 266: Rear Brake

    Rear brake When installing: • Installation is the reverse of the removal proce- dure. – Add brake fluid up to the top of the sight glass. Caution: – Bleed the rear brake circuit. • Do not allow brake fluid to come into contact with Check the function of the brake system.

  • Page 267: Wheels And Tyres

    36 Wheels and tyres Contents Page Technical Data ..........................3 Removing and installing front wheel .................5 Replacing wheel bearings .......................7 Removing left/right wheel bearings ..................7 Installing right/left wheel bearings ...................8 Removing and installing rear wheel ...................9 Removing rear wheel ........................9 Installing rear wheel ........................
  • Page 268 36.2...

  • Page 269: Technical Data

    Technical Data Rim size Front 3.50“ J x13“ MT H 2 Rear 3.50“ J x12“ MT H 2 Vertical runout Front mm (in) 0.3 (0.01) Rear mm (in) 0.3 (0.01) Lateral runout Front mm (in) 0.3 (0.01) Rear mm (in) 0.3 (0.01) Tyre size Front...
  • Page 270 36.4...
  • Page 271 Do not pull handbrake lever with brake calliper re- moved/front wheel removed. C1310000 • Raise the BMW C1 on lifter (arrow), BMW No. 00 1 570, until front wheel is clear of the ground, making sure that the BMW C1 is secure. 36.5...
  • Page 272 – Remove the brake calliper.............See Group 34 • Unscrew hex nut (4). • Slacken pinch bolts (2, 5) in telescopic forks. • Pull out quick-release axle (1), noting spacer (3). • Remove front wheel. When installing: • Installation is the reverse of the removal proce- dure: pay particular attention to the following.

  • Page 273: Replacing Wheel Bearings

    Lay the front wheel rim on two wooden blocks so that the brake disc is free. 00 8 572 00 8 571 36 6 610 C1360030 • Place support ring, BMW No. 36 6 610, on right wheel hub. 36.7...

  • Page 274: Installing Right/Left Wheel Bearings

    Installing right/left wheel bearings Note: Use temperature measuring device, BMW No. 00 1 900, to check heat rise. • Heat bearing seat to 100 °C (212 °F). • Pull out wheel bearing (3) with puller, 36 5 542 BMW No. 00 8 572, and internal puller 21/2, BMW No.

  • Page 275: Removing Rear Wheel

    Do not pull handbrake lever with brake calliper re- • moved/rear wheel removed. Raise the BMW C1 on lifter (arrow), BMW No. 00 1 570, until rear wheel is clear of – Remove silencer system. the ground, making sure that the BMW C1 is se- ............See Group 18...

  • Page 276: Installing Rear Wheel

    C1340030 c1360050 • • Pull rear wheel with spacer (1) and brake-calliper Install spacer sleeve with collar (arrow) toward carrier (2) far enough off the drive axle to permit the inside. • the brake-calliper carrier to be turned forward. Install brake-calliper carrier with brake calliper. •...

  • Page 277: Static Balancing Of Front Wheel

    (2) and spirit level (1). wheel. • • Insert the balancing shaft, BMW No. 36 3 617, Turn knurled nut, BMW No. 36 3 631, until bal- through the front wheel. ancing shaft is hand-tight. • • Turn knurled nut, BMW No. 36 3 617, until bal- Place the rear wheel on the balancer, ancing shaft is hand-tight.

  • Page 278: Checking Front Wheel Rim For Runout

    Checking front/rear wheel 36 32 528 Note: rim for runout Apply the dial gauge, BMW No. 00 2 510, only to the machined inner surface of the wheel rim. Checking front wheel rim for runout • Measure radial run-out and lateral run-out.

  • Page 279: Checking Rear Wheel Rim For Run-Out

    Checking rear wheel rim for run-out Note: – Remove tyre. Apply the dial gauge, BMW No. 00 2 510, only to – Level balancing rig, BMW No. 36 3 600, using the machined inner surface of the wheel rim. knurled-head screws (2) and spirit level (1).
  • Page 280 36.14...
  • Page 281 46 Frame Contents Page Technical Data ..........................5 BMW C1 body and trim overview ..................7 BMW C 1-Trim panel fastening ....................9 Removing and installing front fairing panel .................9 Removing and installing or replacing seat ................9 Removing and installing running-board panel ..............9 Removing and installing or replacing backrest ............
  • Page 282 Contents Page Removing and installing or replacing impact pad ............22 Removing and installing bottom cover for handlebars ................22 Replacing badge ..........................22 Removing and installing or replacing crash element trim ...........23 Removing and installing or replacing crash element ............23 Replacing holder for crash element ..................23 Removing and installing or replacing knee panel ............24...
  • Page 283 Contents Page Replacing stand switch ......................43 Drive swinging arm ........................44 Overview ............................44 Removing drive swinging arm mounts ................44 Link for swinging-arm bearing mount ..................46 Replacing bearing sleeve, right ......................46 Replacing left/right bearing bushing ....................46 Tubular swinging arm ........................47 Removing and installing spacer bushing for tubular swinging arm .............47 Replacing left/right bearing bushings for tubular swinging arm ............47 Replacing right/left Silentblocs for tubular swinging arm ..............48 Installing drive swinging arm mounts...
  • Page 284 46.4...

  • Page 285: Technical Data

    Technical Data Frame Frame Single-tube square steel tube frame with pressed-steel elements and bolted-on lower sec- tion. Engine integrated into frame with load-bear- ing function. Type plate location On frame under the seat Frame No. location On frame under the seat Maximum height (windshield) mm (in) 1766 (69.52) Maximum width (over mirrors)
  • Page 286 46.6...

  • Page 287: Bmw C1 Body And Trim Overview

    BMW C1 body and trim overview C1469010 46.7...
  • Page 288 46.8...
  • Page 289 BMW C 1-Trim panel fastening Removing and installing or 52 53 059 replacing seat – Tighten the trim panel fastenings with a torque wrench. Tightening torques: Fasteners, trim panels to frame ...... 5 Nm Fasteners, trim panels to trim panels ..... 3 Nm Exception: Seat to frame ..........

  • Page 290: Removing And Installing Or Replacing Backrest

    Removing and installing or replac- Removing and installing or ing backrest replacing head restraint – Open the seat. – Remove the backrest. • Remove fastener. • Remove head-restraint cover. 51 14 050 Replacing badge – Remove head restraint. C1460860 • Remove securing screws.

  • Page 291: Removing And Installing Or Replacing Left Or Right Running Board

    C1460030 Removing and installing or Removing and installing or 46 63 225 46 63 327 replacing left or right running board replacing running board centre section • Panel for running board • Remove securing screws: • 2x at bottom in frame •...
  • Page 292 C1460060 Removing and installing or 46 63 221 46 63 223 Removing service cover replacing rear side panel – Remove the rear stowage compartment. – Remove seat – Remove service cover. – Before removing left rear side panel: disengage Bowden cable for seat lock from lock hook. •...

  • Page 293: Luggage Carrier

    C1460131 Luggage carrier 46 54 340 Removing rear stowage compartment – Remove the battery.............See Group 61 46 54 349 Replacing seal for rear stowage • Open lid. compartment • Remove 5 securing screws. 61 21 109 Replacing battery box –...

  • Page 294: Removing And Installing Or Replacing Top Section Of Tunnel

    C1460180 Removing and installing or 46 63 231 replacing top section of tunnel • Turn the handlebars all the way to the left or right. Remove securing screws: • 2x from instrument panel • 2x on tunnel left and right •...

  • Page 295: Removing And Installing Or Replacing Left Or Right Tunnel Panels

    C1460080 Removing and installing or 46 63 228 replacing left or right tunnel panels – Remove service cover. – Remove top tunnel panel. – Remove rubber mat. – Remove running boards. • Remove securing screws: • 3x from running board •...
  • Page 296 C1460070 Removing and installing or 46 63 333 51 16 042 Removing mirror replacing fairing side panel – Remove front fairing panel. – Remove running board. Remove securing screws: • 2x from front frame • 1x running board centre • 2x from holder •...

  • Page 297: Removing And Installing Or Replacing Inside Trim Of C Pillar

    C1460040 Removing and installing or replacing inside trim of C pillar – Remove head restraint. • Remove fasteners. • Remove belt trimmer. Note: Do not pull the strap of the belt - risk of damage. 46.17...

  • Page 298: Removing And Installing Or Replacing Outside Trim Of Shoulder Bar

    C1460050 Removing and installing or 46 63 348 replacing outside trim of shoulder bar – Remove C-pillar inside trim. • Remove fasteners: • 3x from backrest support • 1x from shoulder bar • 1x from frame section • 2x from rear side panel 46.18...

  • Page 299: Removing And Installing Or Replacing Shoulder Bar Crash Element, Left Or Right

    Removing and installing or Removing and installing or 46 51 160 46 51 170 replacing shoulder bar crash element, replacing C-pillar lightweight foam left or right element – Remove head restraint. – Remove transverse support lightweight foam element C1460800 • Remove 2 fasteners (arrows).
  • Page 300 C1460100 Removing and installing or 46 63 323 Tightening torque: replacing rear panel Head restraint ..........21 Nm – Remove spoiler. – Remove head restraint. – C-pillar inside trim, left and right. – Remove rear stowage compartment Note: It is not necessary to remove the belt trimmer. •...
  • Page 301 C1460150 Removing and installing or • 46 63 232 Disconnect cable for instrument from wiring har- ness. replacing instrument panel – Remove front 2 fasteners at top for top tunnel panel C1460250 • Open retainer (arrow). C1460240 • Disconnect cables for headlight. 46.21...

  • Page 302: Removing And Installing Or Replacing Impact Pad

    C1460200 Removing and installing or 46 63 405 51 14 050 Replacing badge replacing impact pad • Remove badge. • Centre new badge and secure in position with adhesive Removing and installing bottom cover for han- dlebars • Remove 4 fasteners (arrow). •...

  • Page 303: Removing And Installing Or Replacing Crash Element Trim

    Removing and installing or Replacing holder for crash 46 63 328 51 11 005 replacing crash element trim element – Remove crash element. Removing and installing or 51 11 001 replacing crash element – Remove instrument panel. C1460290 • Remove 4 outside and 4 inside fasteners (ar- rows) and remove holder.
  • Page 304 C1460160 Removing and installing or 46 63 246 replacing knee panel – Remove centre, left and right tunnel panels. – Remove 4 fasteners from instrument panel. When installing: Make sure that round-section sealing cord is cor- rectly seated. 46.24...

  • Page 305: Removing And Installing Or Replacing Number-Plate Carrier

    Removing and installing or Removing and installing or 46 62 050 46 62 000 replacing number-plate carrier replacing rear mudguard – Remove the rear stowage compartment. – Disconnect battery. – Remove bottom fastener from left spring strut and pivot the spring strut to the rear. C1460870 •...

  • Page 306: Removing And Installing Roof

    Removing and installing roof Removing and installing 46 63 040 51 31 001 windscreen – Remove the backrest. – Remove head restraint. – Remove front fairing panel. – Remove spoiler. – Remove left and right mirrors. – Remove inside trim of C-pillars. –...

  • Page 307: Removing And Installing Or Replacing Foam-Rubber Element Cross Member

    Removing and installing or When installing: 46 63 041 • Installation is the reverse of the removal proce- replacing foam-rubber element cross dure: pay particular attention to the following. member Caution: Make sure that the seal between front windscreen and roof is correctly positioned. •...

  • Page 308: Replacing Roof Stay

    Replacing roof stay 46 51 165 The procedure for replacing the left roof stay is de- scribed below. The procedure for replacing the right roof stay is analogous. – Remove front fairing panel. – Remove left and right mirrors. – Disengage side trim panels from front frame at left and right.

  • Page 309: Replacing Shoulder Bar

    Replacing shoulder bar When installing: 46 51 172 • Installation is the reverse of the removal proce- dure: pay particular attention to the following. The procedure for replacing the left shoulder bar is described below. The procedure for replacing the right shoulder bar is analogous.
  • Page 310 When installing: • Installation is the reverse of the removal proce- dure: pay particular attention to the following. C1460410 • Remove 3 fasteners (arrows) from frame at top. C1460380 • Remove 4 fasteners (arrows) from frame at rear. • Push the roof stay into the clamp, as far as the mark(arrow).
  • Page 311 Removing/installing mirror 51 16 045 bracket The procedure for removing and installing the left mirror bracket is described below. The procedure for removing and installing the right mirror bracket is analogous. – Remove front fairing panel. – Remove left mirror. –...

  • Page 312: Toggle-Lever Mechanism

    C1460450 Toggle-lever mechanism Overview 1 Toggle-lever mechanism with spring strut, front 2 Bowden cable for extending stand 3 Lever for retracting/extending stand 4 Bowden cable retainer, rear 5 Lever for lifting/lowering front wheel 6 Fastener, eyebolt 7 Eyebolts 8 Spring 9 Bowden cable retainer, front 10 Bowden cable for retracting stand 46.32...
  • Page 313 Position lifter (arrow), BMW No. 00 1 570, in such a way that stand can be retracted. • Raise the BMW C1 on lifter (arrow), BMW No. 00 1 570, until front wheel is clear of the ground, making sure that the BMW C1 is se- cure. •...
  • Page 314 C1460480 C1460500 • • Fully slacken locknuts (11, 12) of adjusting Release Bowden cable (arrow) for extending screws. stand from toggle-lever mechanism; if necessary • Push adjusting screws as far as possible through slightly raise lever (5) (parking mechanism, lift/ holders;...

  • Page 315: Replacing Bowden Cables For Stand

    Raise the BMW C1 on lifter (arrow), Install the eyebolts (bottom anchors for springs) in BMW No. 00 1 570, until front wheel is clear of such a way that the eyes are parallel with the vehi- the ground, making sure that the BMW C1 is se- cle's longitudinal axis.
  • Page 316 Removing Bowden cable for 46 52 053 retracting stand C1460480 • Remove fastener (3) for retainer of Bowden cable C1460790 for stand. • Remove circlip (4). • • Remove fastener (2) for eyebolt. Remove cam disc (5) for stand. • •...
  • Page 317 Removing Bowden cable for 46 52 050 extending stand C1460490 • Move lever (3) (parking mechanism: extend/re- C1460530 tract stand) down and then raise it again. • Disengage Bowden cable (arrow) for extending • Remove fastener (arrow) from toggle-lever stand from cam disc of toggle-lever mechanism. mechanism.
  • Page 318 Installing Bowden cables • Installation is the reverse of the removal proce- dure: pay particular attention to the following. Caution: Install the eyebolts (bottom anchors for springs) in such a way that the eyes are parallel with the vehi- cle's longitudinal axis. Make sure that the Bowden cables for extending/re- tracting stand and seat-belt central release are cor- rectly routed.

  • Page 319: Stand

    10 Bowden cable retainer 11 Fastener, retainer of Bowden cable C1310000 • Raise the BMW C1 on lifter (arrow), BMW No. 00 1 570, until the stand can be ex- tended and retracted, making sure that the BMW C1 is secure. 46.39...
  • Page 320 C1460550 C1310000 • • Remove tension springs (4) using hook, Remove left fastener (9) for stand. BMW No. 46 5 721. Caution: Take care not to damage the switch when removing the stand. • Pull the stand down to remove.

  • Page 321: Replacing Tension Spring(S)

    9 Fastener for stand, left 46 5 721 Overview, right C1460550 • Remove tension spring(s) (4) using hook, BMW No. 46 5 721. When installing: • Installation is the reverse of the removal proce- dure: pay particular attention to the following. Note: Make sure that the tension springs are correctly po- sitioned.

  • Page 322: Replacing Actuator Cam

    Replacing actuator cam 46 52 013 When installing: • Installation is the reverse of the removal proce- dure: pay particular attention to the following. Caution: Take care not to damage the switch when installing the cam. Make sure that Bowden cables are correctly seated on the cam discs for the stand.

  • Page 323: Replacing Stand Switch

    Replacing stand switch When installing: • Installation is the reverse of the removal proce- dure: pay particular attention to the following. Caution: Make sure the connecting cable is correctly routed. Make sure the cables do not chaff. Tightening torques: Fastener for switch......... 8 Nm C1460600 •...

  • Page 324: Drive Swinging Arm

    The projection of the link for the swinging-arm bear- • ing mount (4) is wider on the right than on the left! Slightly raise the BMW C1 on lifter (1), Take this into account when installing the link for BMW No. 00 1 570, making sure that the swinging-arm bearing mount (4)! BMW C1 is secure.
  • Page 325 C1460650 C1460670 • • Slacken locknut (1). Note protective cap (1) of Silentbloc and • Remove fastener (3) for engine. washer (2). • Remove fastener (2) securing left Silentbloc to frame. • Remove left bearing pin (4). C1460660 • Remove fastener (1) securing right Silentbloc to frame.

  • Page 326: Link For Swinging-Arm Bearing Mount

    C1460690 Shell Retinax EP2 • Remove bearing bushings (arrow) on left and Tightening torques: right with puller, BMW No. 00 8 572 and internal Bolt for joint..........73 Nm puller (21/3), BMW No. 00 8 574. When installing: • Installation is the reverse of the removal proce- dure: pay particular attention to the following.

  • Page 327: Tubular Swinging Arm

    00 8 574 C1460690 • Remove bearing bushings (arrow) on left and C1460680 right with puller, BMW No. 00 8 572 and internal puller (21/3), BMW No. 00 8 574. • Remove bolt (1) for joint. • Remove tubular swinging arm (3).

  • Page 328: Installing Drive Swinging Arm Mounts

    Installing drive swinging arm mounts 46 71 023 Replacing right/left Silentblocs for tubular swinging arm • Installation is the reverse of the removal proce- dure: pay particular attention to the following. • Lightly coat bearing pin on left with Shell Retinax EP2. •...

  • Page 329: Secondary Swinging Arm

    Remove Silentbloc with mandrel, BMW No. 33 6 691, and C1130050 sleeve, BMW No. 33 6 692. • Slightly raise BMW C1 on lifter (arrow), When installing: • BMW No. 00 1 570. Installation is the reverse of the removal proce- dure.

  • Page 330: Brake-Calliper Carrier

    – Remove brake calliper, but do not disconnect brake hose.............See Group 34 00 8 572 00 8 573 C1460720 • Remove bearing (2) with puller, BMW No. 00 8 572, and internal puller, BMW No. 00 8 573. 46.50...

  • Page 331: Replacing Rubber Element

    Remove rubber element with mandrel, BMW No. 33 6 681, and • Install bearing (2) with sleeve, BMW No. 33 6 682. mandrel, BMW No. 34 1 551, and make sure bearing is seated. When installing: • • Install centering washer (3) and spacer Installation is the reverse of the removal proce- sleeve (4).

  • Page 332: Installing Brake-Calliper Carrier

    ............See Group 34 C1130050 Caution: • Install the ABS sensor cable carefully and secure it Slightly raise BMW C1 on lifter (arrow), with cable ties. BMW No. 00 1 570. Tightening torques: Secondary swinging arm M8 ......21 Nm Secondary swinging arm M10 (+Loctite 243) ..........
  • Page 333 C1460780 • Open cable ties (arrows). • Disconnect plug (1) for right turn indicator. • Remove fastener (2) for rear frame. • Remove fastener (3) securing spring strut to rear frame. • Remove rear frame. When installing: • Installation is the reverse of the removal proce- dure: pay particular attention to the following.
  • Page 334 46.54...
  • Page 335 51 Equipment Contents Page Removing ignition switch/steering lock ................3 Seat lock ............................3 Replacing seat latch ........................3 Removing and installing Bowden cable for seat lock .............4 Replacing seat lock ........................5 Replacing cylinder of lock for rear stowage compartment ........5 51.1...
  • Page 336 51.2...
  • Page 337 Removing ignition switch/ Seat lock 51 25 040 steering lock Replacing seat latch 51 25 252 – Remove right side trim panel. – Open the seat. – Remove instrument panel.............See Group 46 ............See Group 46 C1510020 C1510010 • Unclip retainer (4). •...
  • Page 338 Removing and installing Bowden cable for seat lock Caution: The lever is spring-loaded: take care when removing – Open the seat. the cover of the seat lock. – Remove rear left side panel.............See Group 46 C1510050 C1510025 • Apply thumb pressure to hold lever (2) in posi- •...
  • Page 339 Replacing seat lock Replacing cylinder of lock 51 25 050 51 47 000 for rear stowage compartment – Open the seat. – Remove rear left side panel.............See Group 46 – Remove the rear stowage compartment.............See Group 46 C1510025 C1510060 •...
  • Page 340 51.6...

  • Page 341: General Electrical Equipment

    61 General electrical equipment Contents Page Technical Data ..........................3 Wiring harness ..........................5 General view, from right ........................5 General view, from front .......................6 Replacing wiring harness ......................7 Battery ..............................7 Removing battery ..........................7 Filling and charging the battery ....................7 Installing the battery ........................8 Wipe/wash sensor ........................8...
  • Page 342 Contents Page Replacing interface in front windscreen ............... 17 Removing and installing wiper arms ................18 61.2...

  • Page 343: Technical Data

    Technical Data General electrical equipment Battery 12 V, 14 A/h Fuses Lights Headlight Rectangular, with halogen bulb and manual beam throw adjustment Bulbs High beam/low beam H4 halogen, 12V 60/55W, asymmetric Parking light 12V W5W Brake light/rear light 12V 21/5W Type P25-2 Flashing turn indicator Front...
  • Page 344 61.4...

  • Page 345: Wiring Harness

    Wiring harness General view, from right C1619010 61.5...

  • Page 346: General View, From Front

    General view, from front C1619020 61.6...

  • Page 347: Replacing Wiring Harness

    Replacing wiring harness Filling and charging the battery 61 11 100 61 21 011 – Remove front fairing panel. Battery acid......... Density 1.28 – Remove right side trim panel. – Remove right service cover. – Remove top and right tunnel panels. –...

  • Page 348: Installing The Battery

    Installing the battery Wipe/wash sensor Replacing wipe/wash sensor 61 35 050 Caution: Only reconnect the battery with the ignition – Remove instrument panel. switched off to avoid short-circuiting.............See Group 46 Connect the positive battery lead (+) first, then connect the negative battery lead (—). Make sure that the battery vent pipe is not kinked or blocked.

  • Page 349: Voltage Regulator

    Voltage regulator Replacing voltage regulator 61 31 046 – Remove right rear side trim panel.............See Group 46 C1610050 • Remove fasteners (arrows). • Remove voltage regulator. When installing: • C1610090 Installation is the reverse of the removal proce- dure. •...

  • Page 350: Starter Relay

    Starter relay Replacing starter relay 61 31 390 Caution: Disconnect earth (ground) lead from battery and in- sulate it. – Remove right rear side trim panel.............See Group 46 C1610110 • Remove fasteners for control cable. • Lift starter relay to the right and remove. When installing: •...

  • Page 351: Replacing Intake Strainer

    Removing and installing 67 12 001 When installing: • Installation is the reverse of the removal proce- wipe/wash pump or replacing fluid dure: pay particular attention to the following. reservoir • Make sure that the seal with intake filter (6) be- tween pump and reservoir is correctly seated.

  • Page 352: Filler Hose

    C1610160 Filler hose When installing: • Installation is the reverse of the removal proce- dure: pay particular attention to the following. Removing and installing filler hose • Make sure the hoses do not chaff. • For the sake of clarity, these illustrations show the Install filler hose from below.

  • Page 353: Replacing Inlet Strainer

    Removing and installing filler 31 67 002 funnel – Remove front fairing panel.............See Group 46 – Swing the headlight forward and down. C1610170 • Pry filler funnel (1) out of holder (2). • Disconnect filler hose (3) from filler funnel. When installing: •...

  • Page 354: Removing And Installing Delivery Hose

    C1610180 Removing and installing delivery hose Hose between pump and 61 66 000 interface at front windscreen For the sake of clarity, these illustrations show the vehicle with certain trim panels removed. – Remove instrument panel. – Remove front fairing panel. –...

  • Page 355: Hose Between Interface At Front Windscreen And Spray Nozzles

    Hose between interface at 61 61 002 front windscreen and spray nozzles Caution: Avoid damaging or scratching the windscreen; if necessary mask off the windscreen. • Swing wiper clear of windscreen. C1610190 C1610210 • • Remove rubber grommet (1) from windscreen. Disconnect delivery hose (arrow) from •...

  • Page 356: Replacing Spray Nozzles

    Replacing spray nozzles Adjusting spray nozzles 61 61 005 • Swing wiper clear of windscreen. 45° 15° 45° C1610250 C1610230 • Using a screwdriver, adjust the spray • Unclip spray nozzles (1) from wiper arm. nozzles (arrows) to ensure excellent cleaning •...
  • Page 357 Replacing interface in front windscreen – Remove wiper arms.............See Group 61 Caution: Avoid damaging or scratching the windscreen; if necessary mask off the windscreen. C1610190 • Remove rubber grommet (1) from windscreen. • Remove interface (2). C1610200 • Disconnect delivery hose (arrow) from interface (2).
  • Page 358 Removing and installing 61 61 000 When installing: • Installation is the reverse of the removal proce- wiper arms dure: pay particular attention to the following. Caution: Avoid damaging or scratching the windscreen; if necessary mask off the windscreen. C1610270 •...
  • Page 359 62 Instruments Contents Page Technical Data ..........................3 Instrument cluster ........................5 Wiring colours ..........................5 Removing and installing instrument panel ................6 Replacing wiring harness ......................6 Telltale and warning lights ......................7 Replacing bulbs ..........................7 62.1...
  • Page 360 62.2...

  • Page 361: Technical Data

    Technical Data Instruments Speedometer and fuel-gauge light 12 V 1.7 W Flashing turn indicators, coolant temperature, engine-oil pressure, seat-belt, ABS, full-beam indicator lights 12 V 1.7 W 62.3...
  • Page 362 62.4...

  • Page 363: Instrument Cluster

    C1620010 Instrument cluster Wiring colours violet/black - brown/violet (1) yellow/violet (2) gray/violet - brown/violet (3) white/green (4) brown/black - green/black (5) brown/green - green/black (6) gray/violet - brown/violet (7) white/black (8) violet (9) green/black (10) gray/violet - brown/violet (11) yellow (12) violet/red - brown/violet (13) violet/green (14) red/white (15)

  • Page 364: Replacing Wiring Harness

    Removing and installing Replacing wiring harness 62 11 200 instrument panel – Remove handlebar trim. – Remove instrument panel.............See Group 46 C1620020 • Remove fastener (arrow) for cable clip. • Remove fasteners for cable tab connector. C1620020 • Carefully ease out bulb sockets. •...

  • Page 365: Replacing Bulbs

    C1620010 Telltale and warning lights Replacing bulbs 62 99 181 Right flashing turn indicator repeater (1) – Remove instrument cluster. Light for fuel gauge (3) Telltale light for coolant temperature (5) Telltale light for engine-oil pressure (6) Caution: Speedometer light (7, 11) Do not damage the instrument cluster.
  • Page 366 62.8...
  • Page 367 63 Lights Contents Page Technical Data ..........................3 Headlight ............................5 Removing and installing headlight ...................5 Replacing intermediate frame ....................5 Replacing headlight surround ....................6 Replacing high-beam/ low-beam bulb ..........................6 Replacing bulb for parking light ....................7 Flashing turn indicator ......................7 Replacing front left/right turn indicator .................7 Replacing front left/right turn indicator bulb ...............8...
  • Page 368 63.2...

  • Page 369: Technical Data

    Technical Data Lights Headlight Rectangular, with halogen bulb and manual beam throw adjustment Bulbs High beam/low beam H4 halogen, 12V 60/55W, asymmetric Parking light 12V W5W Brake light/rear light 12V 21/5W Type P25-2 Flashing turn indicator Front 12V 21W Type P25-1 Rear 12V 10W Type P25-1...
  • Page 370 63.4...

  • Page 371: Headlight

    Headlight When installing: • Installation is the reverse of the removal proce- dure: pay particular attention to the following. – Remove front fairing panel. – Swing the headlight forward and down.............See Group 46 Caution: When installing, make sure that the wiring harness is correctly routed and secured.

  • Page 372: Replacing Headlight Surround

    Replacing headlight surround Replacing high-beam/ 63 12 241/250 low-beam bulb – Remove headlight. – Remove intermediate frame. Note: Do not touch inside of reflector and glass of bulbs with bare hands. C1630080 • Remove locking device (2). • Push shaft (1) up and remove. C1630040 •...

  • Page 373: Flashing Turn Indicator

    Replacing bulb for parking Flashing turn indicator 63 99 161 light Replacing front left/right turn 63 13 170 indicator The procedure for removing and installing the left turn indicator is described below. The procedure for replacing the right turn indicator is analogous. –...
  • Page 374 Replacing front left/right turn Replacing left/right rear turn 63 99 271 63 23 020 indicator bulb indicator The procedure for the left turn indicator is described The procedure for the left turn indicator is described below. The procedure for replacing the right turn in- below.

  • Page 375: Rear Lights

    Replacing rear left/right turn Rear lights 63 99 321 indicator bulb Replacing rear light cluster 63 21 380 The procedure for the left turn indicator is described below. The procedure for replacing the right turn in- – Remove the rear stowage compartment. dicator is analogous.
  • Page 376 Replacing bulb for brake light/ 63 99 381 rear light Caution: Always switch off the ignition before changing bulbs. Note: Do not touch inside of reflector and glass of bulbs with bare hands. – Open the rear stowage compartment.............See Group 46 C1630050 •...

  • Page 377: Seat Belts

    72 Seat belts Contents Page Seat belts ............................3 Removing and installing seat-belt central release unit ...........3 Checking operation of seat-belt central release mechanism ........4 Replacing bowden cable with left/right belt buckles ............4 Replacing indicator switches for seat belt ................5 Replacing 3-point seat belt ......................5 Replacing 2-point seat belt ......................7...
  • Page 378 72.2...
  • Page 379 Seat belts Removing and installing 72 11 020 seat-belt central release unit – Open the seat. – Remove instrument panel. – Remove top tunnel panel. – Remove left and right service covers. – Remove left and right rear side trim panels.............See Group 46 •...

  • Page 380: Replacing Bowden Cable With Left/Right Belt Buckles

    Open cable tie (arrow). • Disconnect plug connection for seat-belt switch. C1720050 • Use test gauge (arrow), BMW No. 72 5 501 to tension the red lever • Turn the handlebars all the way to the right and the left.

  • Page 381: Replacing 3-Point Seat Belt

    Replacing 3-point seat belt When installing: 72 11 003 • Installation is the reverse of the removal proce- dure: pay particular attention to the following. – Open the seat. – Remove the backrest. – Remove head restraint. Caution: – Remove the rear stowage compartment. When installing, make sure that the Bowden cable –...
  • Page 382 C1460400 C1720080 • • Disengage seat belt from guide (arrow) at shoul- Remove fastener (arrow) of inertia reel. • der bar. Pull inertia reel down and to the rear to remove. When installing: • Installation is the reverse of the removal proce- dure: pay particular attention to the following.

  • Page 383: Replacing 2-Point Seat Belt

    Replacing 2-point seat belt 72 11 002 – Open the seat. – Remove the backrest. – Remove head restraint. – Remove the rear stowage compartment. – Remove the rear panel. – Remove right C-pillar trim panel. – Remove inside trim from right C-pillar.............See Group 46 C1720070 •...

  • Page 384: Replacing Guide For Seat Belt At Shoulder Bar

    Replacing guide for seat belt at When installing: • Installation is the reverse of the removal proce- shoulder bar dure: pay particular attention to the following. The procedure for replacing the left belt guide is de- Caution: scribed below. The procedure for the right belt When installing, make sure that the seat belt, Bow- guide is analogous.

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