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2000-2003 BMW C1 & C1 200 Service Manual – PDF DOWNLOAD
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2000-2003 BMW C1 & C1 200 Service Manual
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Description
2000-2003 BMW C1 & C1 200 Service Manual
FILE DETAILS:
2000-2003 BMW C1 & C1 200 Service Manual
Language : English
Pages : 458
Downloadable : YES
Format : PDF
Size : 61.1 MB
DESCRIPTION:
2000-2003 BMW C1 & C1 200 Service Manual
INTRODUCTION:
This repair manual will help you to perform all the main maintenance and repair work correctly and efficiently. It should be consulted regularly by workshop personnel as an addition to the practical and theoretical knowledge obtained in Training School courses.
- It is a contribution towards achieving even higher Service quality. All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification.
- The repair manual is structured in the logical sequence of the work to be performed: Removal, Disassembly, Repair, Assembly, Installation. The entire contents are divided into individual chapters, corresponding to the Construction Groups.
TABLE OF CONTENTS:
2000-2003 BMW C1 & C1 200 Service Manual
Preface......................................................................................................... 3 How to use this manual...................................................................................... 4 Explanation of symbols...................................................................................... 4 Contents................................................................................................ 4 Operations.............................................................................................. 4 Contents........................................................................................................ 5 Maintenance schedule............................................................................................ 7 Pre-delivery Check.............................................................................................. 8 Service data.................................................................................................... 9 00 Tightening torques operating fluids.......................................................................... 11 Torque specifications ..................................................... 13 Table of service products................................................................................... 22 00 Pre-delivery check........................................................................................... 25 Check transport container for damage........................................................................ 27 Damage in Germany....................................................................................... 27 Damage in export markets................................................................................ 27 Unpack C1................................................................................................... 28 Place C1 on stand....................................................................................... 29 Take the C1 from the stand.............................................................................. 31 Check C1 for damage......................................................................................... 33 Check package contents to determine whether consignment is complete......................................... 33 Fill and charge the battery................................................................................. 34 Use BMW MoDiTeC/DIS plus to access stored error codes....................................................... 35 Check tyre inflation pressures.............................................................................. 35 Add fuel.................................................................................................... 35 Operation check as final inspection......................................................................... 35 Final cleaning.............................................................................................. 36 Vehicle delivery............................................................................................ 36 00 Maintenance.................................................................................................. 37 Maintenance intervals....................................................................................... 41 1,000 km/600 miles Inspection........................................................................ 41 BMW Service............................................................................................. 41 BMW Inspection.......................................................................................... 41 BMW Annual Service...................................................................................... 41 Reading out BMW MoDiTeC/DIS and error codes stored in ECU................................................... 41 (Inspections I, II, III and IV)......................................................................... 41 Engine oil change........................................................................................... 42 (Inspections I, II, III and IV)......................................................................... 42 Drain engine oil and clean magnetic plug................................................................ 42 Clean oil filter screen................................................................................. 42 Replace oil filter element.............................................................................. 42 Refill engine with oil.................................................................................. 43 Gearbox oil change.......................................................................................... 43 (Inspection III, IV) every 30,000km/18,000 miles or every 3years................................... 43 Checking coolant............................................................................................ 44 (Inspections I and III)................................................................................. 44 Adding coolant.......................................................................................... 44 Change coolant.............................................................................................. 45 (Inspection IV, every 2 years).......................................................................... 45 Drain coolant........................................................................................... 45 Draining expansion tank................................................................................. 45 Adding coolant.......................................................................................... 45 Checking valve clearances................................................................................... 46 (Inspections I, II and III)............................................................................. 46 Swivel out powertrain cradle............................................................................ 46 Checking valve clearances............................................................................... 48 Adjusting valve clearances.............................................................................. 49 Replace spark plug.......................................................................................... 52 (Inspections II and III)................................................................................ 52 Replacing air cleaner element............................................................................... 53 (Inspections II and III)................................................................................ 53 Empty drain pipe from intake-air plenum chamber............................................................. 53 (Inspection IV)......................................................................................... 53 Checking brake lines........................................................................................ 54 (Inspections II and III)................................................................................ 54 Checking brake lines.................................................................................... 54 Checking brake system operation and inspect for leaks....................................................... 54 (Inspections II and III)................................................................................ 54 Checking brake fluid level.................................................................................. 54 (Inspections I, II and III)............................................................................. 54 Checking fluid level in the closed brake fluid reservoir................................................ 54 Checking fluid level in the open brake fluid reservoir.................................................. 55 Checking brake pads and discs for wear/replacing............................................................ 56 (Inspections II and III)................................................................................ 56 Checking brake pads for wear............................................................................ 56 Front brake pads.................................................................................... 56 Rear brake pads..................................................................................... 56 Replacing brake pads.................................................................................... 57 Front brake......................................................................................... 57 Rear brake.......................................................................................... 58 Checking the brake discs................................................................................ 59 Replacing brake fluid....................................................................................... 60 (Inspection IV)......................................................................................... 60 Front brake............................................................................................. 60 Drawing off brake fluid/forcing back brake pistons.................................................. 60 Bleed the front brake circuit....................................................................... 61 Rear brake.............................................................................................. 61 Drawing off brake fluid/forcing back brake pistons.................................................. 61 Bleeding rear brake circuit......................................................................... 62 Variator drive belt replacement............................................................................. 62 (Inspections II and III)................................................................................ 62 Check belt.............................................................................................. 63 Checking clutch lining...................................................................................... 64 (Inspection III)........................................................................................ 64 Clean variator filter screen................................................................................ 64 (Inspections II and III)................................................................................ 64 Drive variator.............................................................................................. 65 Remove drive variator................................................................................... 65 Check, clean and grease drive variator (lubricated version)............................................. 65 (Inspection II, III) (lubricated version)........................................................... 65 Check and clean drive variator (unlubricated version).................................................. 67 (Inspection II, III) (unlubricated version)......................................................... 67 Replacing complete drive variator........................................................................... 68 (Inspection II) every 22,500 km (13,500 miles) – lubricated version only............................. 68 Checking wheel bearing float................................................................................ 69 (Inspection III)........................................................................................ 69 Check to ensure that leading link bearing has zero play..................................................... 70 (Inspection I, IV)...................................................................................... 70 Checking steering bearing play.......................................................................... 70 Check battery electrolyte level - add distilled water if necessary.......................................... 70 (Inspection IV)......................................................................................... 70 Checking battery electrolyte level...................................................................... 70 Adding distilled water.............................................................................. 71 Clean/grease battery terminals if necessary................................................................. 71 (Inspection IV)......................................................................................... 71 Checking Bowden cables...................................................................................... 71 (Inspections III and IV)................................................................................ 71 Checking easy-lift mechanism................................................................................ 71 (Inspections I, II, III and IV)......................................................................... 71 Checking windscreen washer.................................................................................. 72 (Inspections I, II and III)............................................................................. 72 Check windscreen wiper...................................................................................... 72 (Inspections II, III and IV)............................................................................ 72 Checking safety elements.................................................................................... 72 (Inspections I, II, III and IV)......................................................................... 72 Check Bowden cable for central seat- belt release....................................................... 72 Check belt straps and belt buckles...................................................................... 72 Check inertia reels..................................................................................... 72 Check inertia-reel's detent mechanism to ensure that it engages correctly............................... 72 Examine crash elements...................................................................................... 73 (Inspections I, II, III and IV)......................................................................... 73 Check shoulder bar and deformation element.................................................................. 73 (Inspections I, II, III and IV)......................................................................... 73 Measure shoulder bar.................................................................................... 73 Replacing fuel filter....................................................................................... 73 (Inspection II) every 37,500 km (22,500 miles)........................................................ 73 Replacing boot in brake-control assembly (master cylinder), only withoptionalABS.......................... 74 (Inspection III) every 30,000 km (18,000 miles)....................................................... 74 Check mounts................................................................................................ 75 (Inspection I).......................................................................................... 75 Final inspection with road safety and operation check....................................................... 75 (Inspections II, III and IV)............................................................................ 75 Tyre tread depth (recommended minimum).................................................................. 75 Tyre pressures (tyres cold)............................................................................. 75 Roadworthiness check.................................................................................... 75 11 Engine....................................................................................................... 77 C1 engine................................................................................................... 85 C1 lubrication.............................................................................................. 86 C1 drivetrain............................................................................................... 87 # Operations performed with powertrain cradle installed..................................................... 88 Swivel out powertrain cradle................................................................................ 88 Lock engine at TDC.......................................................................................... 90 # Checking valve clearances................................................................................. 91 # Adjusting valve clearances................................................................................ 92 Removing and installing powertrain cradle................................................................... 93 Replacing grooved ball bearing for engine mount......................................................... 95 # Replacing ignition cover.............................................................................. 95 Replacing oil pump...................................................................................... 96 Removing and installing oil pump.................................................................... 96 Measuring oil pump.................................................................................. 97 Water pump removal, installation, replacement........................................................... 97 Removing water pump................................................................................. 97 Replacing shaft oil seals........................................................................... 98 Install water pump.................................................................................. 99 # Replacing oil pressure switch.........................................................................100 # Replacing oil filter..................................................................................100 # Replacing pressure-relief (bypass) valve..............................................................100 # Replacing filter screen...............................................................................101 Replacing oil seal on crankshaft........................................................................101 Removing crankshaft oil seal........................................................................101 Installing crankshaft oil seal......................................................................101 Cylinder head...............................................................................................102 # Dual temperature sensor removal, installation, replacement............................................102 Bucket tappet removal, installation, replacement........................................................102 Inlet and exhaust valve.................................................................................103 Removing valves.....................................................................................103 Check valve guide for wear..........................................................................105 Check valve seat for wear...........................................................................106 Regrinding valve seats..............................................................................106 Check valve for wear................................................................................107 Check valve springs for wear........................................................................107 Install valves......................................................................................108 # Check timing chain........................................................................................109 # Replacing chain tensioner.............................................................................109 # Cylinder head cover removal and installation..........................................................110 Camshaft, camshaft sprocket, camshaft bearing cap......................................................111 Removing and installing camshaft sprockets..........................................................111 Camshaft bearing cap/camshaft removal, installation, replacement....................................112 Checking camshafts..................................................................................114 Replacing chain rails.......................................................................................114 Chain rail replacement..................................................................................114 Replacing guide rail....................................................................................115 Replacing chain tensioner rail..........................................................................115 Timing chain removal, installation, replacement........................................................116 Cylinder head removal and installation..................................................................116 Cylinder liner removal..............................................................................117 Checking cylinder dimensions........................................................................117 Replacing stud bolts................................................................................118 Piston removal, installation, replacement...............................................................118 Replacing piston rings..............................................................................119 Checking piston dimensions..........................................................................120 Measuring piston pin................................................................................120 Removing crankshaft.........................................................................................121 Measuring end float.....................................................................................121 Measuring housing...........................................................................................122 Measuring main bearings.................................................................................122 Replacing bearing shells................................................................................122 Removing bearing shells.............................................................................122 Installing bearing shells...........................................................................123 Replacing cylindrical pin for starter double gear...................................................124 Installing crankshaft...............................................................................124 Measuring end float in housing......................................................................124 Joining halves of crankcase.............................................................................125 12 Engine electrics.............................................................................................127 Replacing spark plug/ignition cable.........................................................................131 Replacing spark plugs...................................................................................131 Replacing ignition cable................................................................................132 Replacing ignition coil.....................................................................................132 Replacing starter...........................................................................................133 Replacing alternator........................................................................................133 Replacing TDC trigger.......................................................................................134 Reluctor removal and installation...........................................................................134 Replacing one-way clutch................................................................................136 Replacing starter double gear...........................................................................136 Replacing one-way clutch gear...........................................................................137 13 Fuel preparation and control.................................................................................139 Removing and installing air filter housing..................................................................141 Removing and installing intake-air plenum chamber...........................................................141 Removing and installing throttle-valve assembly.............................................................143 Injector....................................................................................................144 Removing and installing injectors.......................................................................144 Replacing injector......................................................................................144 Replacing injection nozzle holder.......................................................................145 Replacing BMS control unit..................................................................................145 16 Fuel tank and lines..........................................................................................147 Removing and installing fuel tank...........................................................................151 Replacing fuel filter.......................................................................................153 Fuel pump unit..............................................................................................154 Removing, installing fuel pump assembly.................................................................154 17 Radiator.....................................................................................................157 Coolant circuit.............................................................................................161 Removing and installing coolant hoses.......................................................................163 Opening hose clamps.....................................................................................163 Closing hose clamps.....................................................................................163 Replacing feed hoses to radiator........................................................................163 Hose between radiator and elbow.....................................................................163 Hose between elbow and coolant pipe.................................................................163 Hose between elbow and refill reservoir.............................................................164 Vent hose...........................................................................................164 Replacing return hose to radiator.......................................................................164 Hose between radiator and coolant pipe..............................................................164 Installing coolant hoses................................................................................164 Replacing coolant hoses on engine......................................................................165 Remove engine coolant hoses.........................................................................165 Replacing coolant hoses.............................................................................165 Replacing thermostat................................................................................165 Install engine coolant hoses........................................................................165 Removing and installing coolant pipes.......................................................................166 Removing engine coolant feed pipe.......................................................................166 Removing engine coolant return pipe.....................................................................167 Installing coolant pipes................................................................................167 Replacing vapour discharge hose.............................................................................168 Removing and installing expansion tank......................................................................169 Changing coolant............................................................................................170 Draining coolant........................................................................................170 Drain coolant from supply line/engine..............................................................170 Draining coolant from return line...................................................................171 Draining coolant from expansion tank................................................................171 Adding coolant..........................................................................................171 Add coolant to feed and return lines and engine.....................................................171 Filling expansion tank with coolant.................................................................172 Checking coolant level..............................................................................172 Checking cooling system for leaks...........................................................................172 Removing and installing radiator with fan...................................................................173 Removing and installing front frame with radiator.......................................................173 Removing and installing radiator with fan shroud in front frame.........................................174 Replacing radiator......................................................................................175 Replacing fan...........................................................................................175 Replacing air duct......................................................................................175 Replacing refill reservoir..................................................................................176 18 Exhaust system...............................................................................................177 Removing and installing silencer heat shield................................................................181 Removing and installing silencer system.....................................................................181 Removing and installing oxygen sensor.......................................................................183 21 Clutch.......................................................................................................185 Centrifugal coupling........................................................................................189 Checking clutch.........................................................................................189 Removing/replacing clutch...............................................................................189 Check spring............................................................................................190 Install clutch..........................................................................................191 24 Gearbox......................................................................................................193 C1 gearbox..................................................................................................197 # Operations with powertrain cradle installed...............................................................198 # Variator replacement......................................................................................198 Removing variator.......................................................................................198 Removing variator driven plate......................................................................198 Removing variator drive plate.......................................................................199 Installing variator.....................................................................................200 Install drive variator (lubricated version).........................................................200 Install drive variator (unlubricated version).......................................................200 Installing driven variator..........................................................................201 Disassembling, checking and assembling drive variator.......................................................202 Dismantling drive variator..............................................................................202 Dismantling drive variator (unlubricated version)...................................................202 Dismantle drive variator (lubricated version).......................................................202 Inspect individual components of drive variator.........................................................203 Variator cover......................................................................................203 Checking belt.......................................................................................203 Check crankshaft journal............................................................................203 Check bearing tube (spacer).........................................................................203 Check primary external plate........................................................................203 Check drive wheel...................................................................................204 Checking rollers....................................................................................204 Check guides and spring clips for wear.............................................................205 Assemble drive variator.............................................................................205 Dismantling, testing and assembling drive variator..........................................................206 Checking individual components of driven variator.......................................................206 Check variator shaft................................................................................206 Dismantling driven variator.........................................................................207 Checking individual components..........................................................................207 Checking bearing....................................................................................208 Replace grooved ball bearing and needle bearing for secondary inside plate.........................208 Assembling driven variator..........................................................................209 Variator - reduction gear unit..............................................................................210 Replace shaft oil seal for variator shaft in gearbox cover (shaftinstalled)............................210 Dismantling and assembling gearbox, checking individual components......................................211 # Operations with powertrain cradle installed.......................................................211 Preparations........................................................................................211 # Gearbox cover removal.................................................................................212 # Gearbox shaft removal.................................................................................212 # Replacing housing shaft oil seal on output shaft......................................................213 Replacing shaft oil seal for variator shaft in gearbox cover (shaft removed)............................214 #Replacing grooved ball bearing for variator shaft in gearbox cover................................214 # Replacing grooved ball bearing for variator shaft in housing......................................215 # Replacing grooved ball bearing for output shaft in cover.........................................216 Replacing grooved ball bearing for output shaft in housing..........................................217 # Checking dimensions of gearbox shafts.................................................................218 Checking and measuring variator shaft...............................................................218 Testing and measuring intermediate shaft............................................................219 Testing and measuring output shaft..................................................................219 31 Front forks..................................................................................................221 Removing and installing telescopic forks and fork cross brace...............................................225 Removing telescopic fork................................................................................225 Removing and installing fixed tube......................................................................226 Removing fork cross brace...................................................................................227 Fork cross brace; components............................................................................228 Dismantling fork cross brace............................................................................228 Removing pot-type joints............................................................................228 Installing pot-type joints..........................................................................229 Removing ball bearing with stud.....................................................................229 Installing ball bearing and stud....................................................................230 Installing fork cross brace.............................................................................230 Installing telescopic fork..............................................................................231 Replacing seal rings for telescoping tube...................................................................231 Removing telescopic tube cross brace with telescopic tubes..............................................231 Replacing telescopic tube seal..........................................................................233 Remove seal.........................................................................................233 Install seal........................................................................................233 Replace seal telescopic tube/seal holder................................................................234 Remove seal holder..................................................................................234 Install seal holder.................................................................................234 Replace guide bush......................................................................................235 Replacing telescopic tube...............................................................................236 Replacing telescopic tube cross brace...................................................................237 Replacing ball joint....................................................................................238 Installing telescopic tube cross brace with telescopic tubes............................................238 Measuring telescopic fork...................................................................................239 Examining telescoping tube cross brace and fork cross brace.............................................239 Checking runout of fixed tube...........................................................................239 Removing and installing front spring strut..................................................................239 Replacing spring/shock absorber.............................................................................243 Removing and installing leading link........................................................................243 Removing leading link...................................................................................243 Replacing left and right taper- fit ball bearings for leading link......................................245 Installing leading link.................................................................................245 32 Steering.....................................................................................................247 General view of handlebar...................................................................................251 Heated grips................................................................................................252 Heated grip, removing and installing on left side.......................................................252 Heated grip, removing and installing on right...........................................................253 Removing and installing left/right brake-control assemblies.................................................254 Replacing left/right brake lamp switch......................................................................255 Replacing seal in brake unit (master cylinder) with optional ABS only.......................................256 Removing and installing left and right handlebar levers.....................................................257 Removing and installing handlebar...........................................................................257 Replacing throttle cable....................................................................................259 33 Rear wheel drive.............................................................................................261 Auxiliary swing arm.........................................................................................265 Removing auxiliary swing arm............................................................................265 Replacing Silentblocks..................................................................................265 Installing auxiliary swing arm..........................................................................265 Removing and installing left/ right spring strut............................................................266 Replacing spring/shock absorber.............................................................................267 34 Brakes.......................................................................................................269 Brake caliper backplate.....................................................................................273 Removing brake-caliper carrier..........................................................................273 Replacing brake caliper carrier bearing................................................................273 Replacing rubber bush...................................................................................274 Installing brake-caliper carrier........................................................................275 Front brake caliper.........................................................................................275 Removing and installing brake caliper...................................................................275 Rear brake caliper..........................................................................................276 Removing and installing rear brake caliper..............................................................276 Removing and installing front brake disc....................................................................279 Removing and installing rear brake disc.....................................................................279 Front ABS wheelspeed sensor, removal and installation.......................................................280 Replacing front ABS reluctor................................................................................281 Removing and installing rear ABS sensor.....................................................................282 Replacing rear ABS reluctor................................................................................283 Checking and adjusting ABS wheelspeed sensor gap............................................................283 Front wheel.............................................................................................283 Rear wheel..............................................................................................284 Removing and installing ABS control unit....................................................................284 Removing and installing front brake lines/hoses.............................................................287 Replacing front brake hose – withoutABS................................................................287 Removing front brake lines/hoses – (with ABS)...........................................................289 Brake hose between front wheel and brake line, ABS control unit.....................................289 Brake line between brake hose, front wheel and ABS control unit.....................................289 Brake line between brake hose, right brake handlebar fitting and ABS control unit...................289 Brake hose between right brake handlebar fitting and brake line, ABS control unit...................290 Installing front brake lines/hoses – (with ABS).........................................................290 Removing and installing rear brake lines/hoses..............................................................290 Brake hose between brake unit on left and brake line...................................................290 Brake line between brake hose, left brake-control assembly, and brake hose to brake caliper - wit.......292 Brake lines between brake hose, left brake-control assembly, and brake hose to brake caliper - wi.......293 Brake lines between brake hose, brake handlebar fitting and ABS control unit........................293 Brake lines between ABS control unit and brake hose to brake caliper................................294 Brake hose between brake line and brake caliper.........................................................296 Checking brake pads and discs for wear/replacing............................................................297 Checking brake pads for wear............................................................................297 Front brake pads....................................................................................297 Rear brake pads.....................................................................................297 Replacing brake pads....................................................................................298 Front brake.........................................................................................298 Rear brake..........................................................................................299 Checking the brake discs................................................................................300 Checking brake fluid level..................................................................................301 Checking fluid level in the closed brake fluid reservoir................................................301 Checking fluid level in the open brake fluid reservoir..................................................302 Replacing brake fluid and bleeding brake system.............................................................303 Front brake.............................................................................................303 Drawing off brake fluid/forcing back brake pistons..................................................303 Bleeding front brake circuit........................................................................303 Rear brake..............................................................................................304 Drawing off brake fluid/forcing back brake pistons..................................................304 Bleeding rear brake circuit.........................................................................304 36 Wheels and tyres.............................................................................................305 Removing and installing front wheel.........................................................................309 Replacing wheel bearings....................................................................................311 Removing left/right wheel bearings......................................................................311 Installing right/left wheel bearings....................................................................312 Removing and installing rear wheel..........................................................................313 Removing rear wheel.....................................................................................313 Installing rear wheel...................................................................................314 Static balancing of front and rear wheels..................................................................315 Static balancing of front wheel.........................................................................315 Static balancing of rear wheel..........................................................................315 Checking front/rear wheel rim for runout....................................................................316 Checking front wheel rim for runout.....................................................................316 Checking rear wheel rim for runout......................................................................317 46 Frame........................................................................................................319 C1 - Trim Overview..........................................................................................325 C1 - Trim mount.........................................................................................327 Removing and installing front trim......................................................................327 Running board cover removal and installation............................................................327 Left and right lower panel removal, installation, replacement...........................................328 Panel centre section removal, installation, replacement.................................................328 Rear side trim removal, installation, replacement.......................................................329 Service hatch removal and installation..............................................................329 Rear storage compartment cover..........................................................................330 Replacing seal on rear storage compartment..........................................................330 Replacing battery compartment.......................................................................330 Remove the rear storage compartment.................................................................330 Upper tunnel removal, installation, replacement.........................................................331 Left/right tunnel removal, installation, replacement....................................................332 Side panel removal, installation, replacement...........................................................333 Replacing plaque for side panel.....................................................................333 C-pillar inner trim removal, installation, replacement..................................................334 Shoulder bar external trim, removal, installation, replacement..........................................335 Shoulder bar crash element, left or right, removal and installation.....................................336 C-pillar foam element, removal, installation, replacement...............................................336 Rear trim removal, installation, replacement............................................................337 Instrument trim removal, installation and replacement...................................................338 Impact panel removal, installation, replacement.........................................................339 Lower handlebar cover...............................................................................339 Replacing badge.....................................................................................339 Crash element trim removal, installation, replacement...................................................340 Crash element removal, installation, replacement........................................................340 Replacing holder for crash element......................................................................340 Knee trim removal, installation, replacement............................................................341 Licence plate bracket removal, installation, replacement................................................342 Rear mudguard removal, installation, replacement........................................................342 Large storage compartment...................................................................................343 Replacing cover.........................................................................................343 Storage compartment removal and installation............................................................343 Replacing the power socket..............................................................................344 Roof removal and installation...............................................................................345 Windscreen removal and installation.........................................................................345 Cross brace foam element; removal, installation, replacement............................................346 Roof bar replacement........................................................................................347 Shoulder bar replacement....................................................................................349 Checking shoulder bar alignment.............................................................................350 Articulated joint mechanism.................................................................................351 Overview................................................................................................351 Removing and installing articulated joint mechanism.....................................................352 Articulated joint hand lever mechanism removal and installation.........................................355 Large hand lever removal and installation...........................................................355 Small hand lever removal/installation...............................................................357 Replacing control disc for large hand lever.........................................................359 Replace stand Bowden cables.................................................................................360 Removing Bowden cable for retracting stand..............................................................360 Removing Bowden cable for extending stand...............................................................361 Bowden cable installation/adjustment....................................................................362 Stand.......................................................................................................363 Overview................................................................................................363 Removing/installing stand...............................................................................363 Stand bearings..........................................................................................365 Overview, left......................................................................................365 Overview, right.....................................................................................365 Greasing the bearings...............................................................................366 Replacing tension spring(s).............................................................................366 Lobe/overload guard transfer element replacement........................................................366 Replacing stand switch..................................................................................367 Powertrain cradle...........................................................................................368 Overview................................................................................................368 Removing powertrain cradle mounts.......................................................................368 Coupling for swing arm bearing..........................................................................370 Replacing bearing sleeve, right.....................................................................370 Replacing left/right bush...........................................................................370 Tubular swing arm.......................................................................................371 Removing and installing spacer bush for tubular swing arm...........................................371 Replacing left/right bearing bushings for tubular swinging arm.....................................372 Replacing right/left Silentblocs for tubular swing arm.............................................372 Installing powertrain cradle mounts.....................................................................373 Rear frame member replacement...............................................................................373 Luggage system bracket......................................................................................374 Bracket removal and installation........................................................................374 Upper bracket removal and installation..................................................................375 Support base removal and installation...................................................................375 Luggage system lock carrier removal and installation....................................................376 Luggage hook replacement................................................................................376 Topcase.....................................................................................................377 Hinge replacement.......................................................................................377 Replacing inside lock...................................................................................377 51 Equipment....................................................................................................379 Removing ignition switch/ steering lock.....................................................................381 Replacing seat lock.........................................................................................381 Rear storage compartment lock barrel replacement...........................................................382 Replacing lock barrel on large/small storage compartment....................................................382 Replacing Topcase lock barrel...............................................................................383 Replacing lock barrel on luggage rail......................................................................383 Mirror removal and installation.............................................................................384 Mirror bracket removal and installation.....................................................................385 52 Seat.........................................................................................................387 Seat removal, installation, replacement.....................................................................389 Open the seat...........................................................................................389 Remove seat.............................................................................................389 Heated seat removal, installation, replacement..........................................................389 Install seat............................................................................................389 Backrest removal, installation, replacement.................................................................390 Head restraint removal, installation, replacement...........................................................390 Replacing badge.........................................................................................390 Seat lock replacement......................................................................................391 Seat lock Bowden cable removal and intallation..........................................................391 61 General electrical equipment.................................................................................393 Wiring harness..............................................................................................397 General view, from right................................................................................397 General view, from front................................................................................398 Replacing wiring harness................................................................................399 Wiring harness section plug connections.............................................................399 Adapter cable for optional equipment................................................................400 Wipe/wash sensor............................................................................................400 Replacing wipe/wash sensor..............................................................................400 Combination switch..........................................................................................401 Combination switch, left, removal and installation......................................................401 Combination switch, right, removal and installation.....................................................402 Battery.....................................................................................................403 Remove the battery......................................................................................403 Filling and charging the battery........................................................................404 Installing the battery..................................................................................404 Voltage regulator...........................................................................................405 Replacing voltage regulator.............................................................................405 Starter relay...............................................................................................405 Replacing starter relay.................................................................................405 Removing and installing wipe/wash pump and replacing fluid reservoir........................................406 Replacing intake strainer...............................................................................407 Removing and installing filler funnel...................................................................407 Replacing filler strainer...............................................................................407 Filler hose.................................................................................................408 Removing and installing filler hose.....................................................................408 Removing and installing delivery hose.......................................................................409 Hose between pump and interface at front windscreen.....................................................409 Hose between interface at front windscreen and spray nozzles............................................410 Replacing spray nozzles.....................................................................................411 Adjusting spray nozzles.....................................................................................411 Replacing passage in front windscreen......................................................................412 Wiper motor replacement.....................................................................................412 Removing and installing wiper arms..........................................................................414 62 Instruments..................................................................................................415 Instrument cluster..........................................................................................419 Wiring colours..........................................................................................419 Removing and installing instrument panel................................................................420 Replacing wiring harness................................................................................420 Fuel gauge replacement..................................................................................421 Speedometer replacement.................................................................................421 Indicator and warning lights............................................................................422 Replacing bulbs.........................................................................................422 63 Lights.......................................................................................................423 Headlight...................................................................................................427 Removing and installing headlight.......................................................................427 Replacing intermediate frame............................................................................427 Replacing headlight bezel...............................................................................428 Replacing high-beam/low- beam bulb.....................................................................428 Replacing parking light bulb............................................................................429 Checking headlight beam angle...........................................................................429 Height adjustment...................................................................................429 Lateral adjustment..................................................................................430 Turn signal.................................................................................................430 Replacing front left/right turn signal..................................................................430 Replacing front left/right turn signal bulb.............................................................431 Replacing left/right rear turn signal...................................................................431 Replacing rear left/right turn signal bulb..............................................................432 Rear lights.................................................................................................432 Replacing taillamp cluster..............................................................................432 Replacing bulb for brake light/ rear light..............................................................433 Map light...................................................................................................434 Map light bulb replacement..............................................................................434 65 Optional extras..............................................................................................435 Alarm system (DWA)..........................................................................................437 Service and maintenance notice..........................................................................437 Applies to all service and maintenance operations...................................................437 When working with BMW MoDiTeC/DISplus diagnostic system............................................437 Activating and checking operation of alarm system.......................................................437 Activating the system...............................................................................437 Deactivating the immobilizer........................................................................438 Supplementary (manual) activation of the alarm function (with immobilizer already active)...........438 Deactivating the immobilizer and alarm functions....................................................438 Programming the alarm system............................................................................439 Activating the programming mode.....................................................................439 Programming the system..............................................................................440 Programming the system to modeB....................................................................440 Indicator LED replacement...............................................................................441 Control unit replacement................................................................................441 Receiver replacement....................................................................................442 Motion sensor replacement...............................................................................443 Replacing alarm system bracket..........................................................................444 Fun audio system............................................................................................445 Volume control replacement..............................................................................445 Amplifier replacement...................................................................................446 Speaker removal, installation, replacement..............................................................446 Replacing left/right speaker brackets...................................................................447 Audio module replacement................................................................................448 72 Seat belts...................................................................................................449 Seat belts..................................................................................................451 Removing and installing central belt release mechanism..................................................451 Checking operation of central belt release mechanism....................................................452 Inertia reel replacement................................................................................452 Replacing Bowden cable with belt buckles on left/right..................................................453 Replacing indicator switches for seat belt.............................................................453 Replacing 3-point seat belt.............................................................................454 Replacing 2-point seat belt.............................................................................456 Replacing guide for seat belt at shoulder bar...............................................................457
2000-2003 BMW C1 & C1 200 SERVICE MANUAL – PDF DOWNLOAD:
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