Bmw C1-200 (2001) User Manual [ru]

Repair manual

C1
C1 200

BMW Motorrad
After Sales

Published by BMW Motorrad

After Sales
UX-VS-2

All rights reserved. Reprints, translation and duplication allowed exclusively with prior written permission
from the publisher.
Errors and omissions excepted. We reserve the right to introduce technical modifications at any time.

Printed in Germany 03/01

Preface

This Repair Manual is intended to assist you in performing all essential maintenance and repair operations
to a professional standard. In its role as a reference source for service personnel, it supplements and ex­pands upon the theoretical and hands-on instruction provided at our training centres to enhance the quality
of our service.

A new edition of this manual will be issued in response to required revisions or the need to incorporate ad­ditional information (supplements).

The illustrations and descriptions contained in this manual apply exclusively to standard, unmodified BMW
Motorcycles and/or BMW Motorcycles equipped with factory-approved BMW accessories and options.

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

•

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

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

•

11 10.

Chap. chapter page continued

A reference arrow with chapter and page calls your attention to additional information contained in another
section of the manual.

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

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

•

tion routines are numbered I, II, III and IV. To help in maintaining a continuous, logical work sequence,
these same numerical designations are employed to identify the subsequent sections describing the ac­tual repair operations.

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

•

When the need arises, repair instructions are also issued in the form of Service Information Bulletins. This
information is then incorporated into subsequent editions of the repair manual. We also recommend the
lavishly illustrated Electronic Parts Catalogue as a supplementary source of information.

When individual steps within an overall operation only apply to motorcycles with specific accessories or
optional equipment, the options to which the steps refer are identified by brackets at the start of the line,
such as

Please devote your careful attention to the following pages with their explanations describing the symbols
used in the manual and their significance.

BMW Motorrad
After Sales

[with heated grips]

.

Published by BMW Motorrad

After Sales
UX-VS-2

80788 München

All rights reserved. Reprints, duplication and translation, in whole or part, are allowed exclusively with prior
written permission.
We reserve the right to introduce technical modifications at any time. Errors and omissions excepted.

Printed in Germany

How to use this manual

Each chapter starts with a table of contents.

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

Chapter 00 describes maintenance procedures and provides general information as well as the pre-delivery
inspection; it furnishes all torque specifications along with listings of fluids and lubricants.

Explanation of symbols

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

Special notices for more efficient procedures

L

Note:

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

e

Attention:

Special information and precautionary notices to prevent damage to the motorcycle. Failure to observe
these mandatory precautions may invalidate the warranty.

d

Warning:

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

Contents

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

Operations

Operations

•

A dot or period identifies individual procedures described under a title

•

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

Remove means:
to completely unscrew a retaining component (such as a bolt or screw)
or
to detach a component (such as an injection rail) and move it enough to gain access to assemblies installed
behind it (such as a throttle-valve).

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

X

Torque specifications:

These data are indicated whenever torques deviate from the standards defined in DIN EN 24 014 and
DIN 912 ISO.

Contents

<< Back

Group / Chapter

00 Tightening torques operating fluids
00 Pre-delivery check
00 Maintenance

11 Engine

12 Engine electrics

13 Fuel preparation and control

16 Fuel tank and lines

17 Radiator

18 Exhaust system

21 Clutch

24 Gearbox

31 Front forks

32 Steering

>> Continuation

Group / Chapter

33 Rear wheel drive

34 Brakes

36 Wheels and tyres

46 Frame

51 Equipment

>> Continuation

52 Seat

61 General electrical equipment

62 Instruments

63 Lights

65 Optional extras

72 Seat belts

<< Back

BMW Motorrad
Maintenance schedule
C1, C1 200

Customer Licence No. Mileage

Job Order No. Date Mechanic's signature

MoDiTeC/DIS plus

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

If the vehicle is ridden for short distances only or at outside temperatures below 0° C (32° F): every 3 months or after
every 3,000 km (1,800 miles) at the latest

Clean oil strainer and magnetic plug

Change transmission fluid

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

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

Change the coolant

every 2 years

Check valve clearances and adjust if necessary

Replacing spark plug

Replace air filter element

shorten change interval if severely dirty or dusty

Drain condensate drain hose from air manifold

Brake hoses and connections: check condition and routing

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

Inspect brake fluid level at front/rear

Examine brake pads and discs for wear, renew if necessary

brake fluid

Renew

Replace variator belt

Check clutch liner, replace if necessary

Cleaning mesh filter of variator

Grease driving variator (greased version)

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

Replace complete driving variator

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

Check wheel bearings for play; replace if necessary

Checking that leading-link mounts are free of play

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

Clean and grease the battery terminals, if necessary

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

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

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

freely without binding; check free travel and adjust as required

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

Check windscreen wiper; replace wiper blade if necessary

Safety elements: check cable for release, belt buckles, belt strap, inertia reels, and belt locks

Check crash element for damage

Inspect shoulder bar for damage, replace deformation element if necessary

Replace fuel filter

every 37,50 0 km/22,500 miles

Only ABS: Replace seal in brake master cylinder

every 30,000 km/18,000 miles

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

Final inspection with road safety and functional check:
– Clutch engagement, steering, front and rear brake

– Condition of tyres and wheels, tyre inflation pressure
– Lights and signalling equipment, telltale and warning lights, instruments
– If necessary, test ride

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

, read fault code memory

*)

at least

*)

*)

once a year

*)

*)

*)

*)

*)

*)

*)

*)

BMW Inspection

at 10,00 km/600 miles

BMW Maintenance

Service every

7,500 km/4,500 miles

BMW Inspection

every 15,000 km/

9,000 miles

BMW

Annual Service

UX-VS-2, 10.2001

BMW recommends Castrol

BMW Motorrad
Pre-delivery Check
C1, C1 200

Customer Registration number

Order no. Signature of mechanic

Inspect transportation packaging for damage

C1:

–Unpack
– Inspect for damage

–Attach parts
–Clean

Battery:

–Remove
– Pour in electrolyte
–Charge
–Grease terminals
– Install (mark date of installation)

BMW
Pre-delivery Check

Inspect complete scope of supply:

– Toolkit
– Documentation
–Keys
– Scope of optional equipment

Inspect tyre inflation pressure

Pour in fuel

Operational check as final inspection:

– Engine idling
– Clutch, clutch engagement
–Steering
–Seat belt
– Easy-lift mechanism
– Brakes, front and rear
– Lights and signalling equipment, telltale and warning lights, instruments
–Set headlight
– If necessary, test ride

UX-VS-2, 10.2001

BMW recommends Castrol

BMW Motorrad
Service data
C1, C1 200

Item Specified

value

Oil capacities

Engine (with filter)

Gearbox

Coolant

Cooling system
Expansion tank

Windshield washer fluid

Brake fluid
Valve clearances

Measured cold, maximum 35 °C (95 °F)

Spark plugs

Electrode gap 0.8…0.9

Idle speed
Tyre pressures (tyres cold)

Solo
Full load

Tightening torques:

Engine oil drain plug
Oil strainer to engine
Engine water drain plug
Oil filter cover
Camshaft gears to camshaft
Guide rail to camshaft support
Chain tensioner plug
Camshaft bearing bridge
Valve cover
Machine bolt TDC setting
Spark plug
Driving variator
Driving variator cover
Driven variator
Locknut of clutch to driven variator
Variator cover to power train link
Ventilation cover for variator
Front stub axle
Clamping bolts for front stub axle
Brake calliper at fork slider tube
Bleed screw in brake calliper
Cover of handbrake control
Rear stub axle,
Exhaust to cylinder head
Auxiliary link to power train link M8
Auxiliary link to power train link M10
Silencer to auxiliary link
Suspension strut to power train link/brake calliper holder
Link mounting to power train link
Tubular link to frame
Stand to frame
Rubber element to tubular link
Cladding bolts

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

use nut only once

1.0 (0.22)

0.090 (0.020)

1.25 (2.2)

0.2 (0.35)

1.0 (1.8) litres (Imp pints)

Inlet: 0.05…0.14

(0.002…0.006)

Exhaust: 0.20…0.29

(0.009…0.010)

(0.031…0.035)

1900 rpm

Front/rear

1.9/2.1 (27.6/30.5)

1.9/2.4 (27.6/34.8)

20
30
10
10
30
10
35
10
10
15
15
60

4
60
50
10

9
30
21
41
14

Hand-tight

130

15
21
60
21
21
73
73
41
42

2.8

Unit of measure or

specification

litres (Imp pints)

15W40

litres (Imp pints)

API GL 4

litres (Imp pints)
litres (Imp pints)

Mixing ratio:
Water: 50%
Antifreeze: 50%
Protection down to
–25 °C (-13 °F)

Water and cleaning prod-

uct, antifreeze as required

DOT 4

mm

(in)

mm

(in)

NGK CR8 EB

mm

(in)

bar (psi)
bar (psi)

Nm
Nm
Nm

Nm
Nm (Loctite 243)
Nm (Loctite 243)

Nm

Nm

Nm

Nm

Nm
Nm (Loctite 243)

Nm

Nm
Nm (Loctite 243)

Nm

Nm

Nm

Nm

Nm

Nm

Nm

Nm

Nm

Nm
Nm (Loctite 243)

Nm

Nm

Nm

Nm

Nm

Nm

Nm

00

00 Tightening torques

operating fluids

Contents

Torque specifications

11 Engine

...........................................................................................................................................3

12 Engine electrical system
13 Fuel injection system
16 Fuel tank

.......................................................................................................................................4

17 Cooling system
18 Silencer (muffler)
21 Clutch
24 Gearbox
31 Front forks
32 Steering

............................................................................................................................................5

........................................................................................................................................5

...................................................................................................................................6

........................................................................................................................................6

33 Final-drive unit
34 Brakes
36 Wheels
46 Frame
51 Equipment
52 Seats

...........................................................................................................................................7

..........................................................................................................................................8

............................................................................................................................................8

...................................................................................................................................9

............................................................................................................................................ 10

61 Electrical equipment
62 Instruments
63 Lights

........................................................................................................................................... 11

............................................................................................................................... 11

65 Optional extras
72 Seat belts

................................................................................................................................... 11

.................................................................................................................3

..............................................................................................................4

.........................................................................................................................4

.......................................................................................................................5

...........................................................................................................................7

............................................................................................................. 10

........................................................................................................................ 11

Page

.......................................................................................................4

Table of service products

....................................................................................................... 12

00.1

00.2

00

Torque specifications

Model C1

Connection

11 Engine

Oil drain plug, magnetic Nm 20

Threaded plug, oil strainer Nm 30

Oil filter cover Nm 10

Threaded TDC set plug Nm 15

Alternator

Alternator cover up to engine no.: 745 594 Nm 10

Alternator cover from engine no.: 745 595 Nm 12

Ignition trigger, Tapite screw Nm 6 LOCTITE 243

Holder for alternator cable, Tapite screw Nm 6 LOCTITE 243

Reluctor to crankshaft, locking fluid Nm 30 LOCTITE 243

One-way clutch, locking fluid Nm 30 LOCTITE 243

Alternator to cover Nm 10

Chain tensioning rail, locking fluid Nm 10 LOCTITE 243

Cylinder head

Cylinder head cover Nm 10

Collar nut Nm 30 ±1

Securing screw Nm 10

Spark plug Nm 15

Camshaft sprockets, locking fluid Nm 30 LOCTITE 243

Bearing cap Nm 10

Chain guide, locking fluid Nm 10 LOCTITE 243

Plug for chain tensioner Nm 35

Vent screw Nm 9

Dual temperature sensor, locking fluid Nm 15 LOCTITE 243

Housing

Starter motor Nm 10

Oil pressure switch, locking fluid Nm 12 LOCTITE 243

Oil pressure valve Nm 30

Stud (tie bolt) Nm 10

Housing screws Nm 10

Oil pump, Tapite screw Nm 6 LOCTITE 243

Water-pump housing, Tapite screw Nm 6 LOCTITE 243

Spring strut at bottom Nm 21

00.3

Model C1

Connection

12 Engine electrical system

Spark plug Nm 15

Ignition coil to frame Nm 5

Ignition trigger, Tapite screw Nm 6 LOCTITE 243

Reluctor to crankshaft, locking fluid Nm 30 LOCTITE 243

One-way clutch, locking fluid Nm 30 LOCTITE 243

Alternator to cover Nm 10

Starter motor Nm 10

Model C1

Connection

13 Fuel injection system

Fuel filter clamp Nm 5

Holder for injection nozzle (self-tapping) Nm 4 LOCTITE 243

Pressure regulator clamp Nm 9

BMS control unit Nm 5

Intake manifold Nm 9

Air plenum clamp Nm Hand-tight

Air filter housing (inner/outer) Nm 9

Throttle cable Nm 8

Spring strut at bottom Nm 21

Model C1

Connection

16 Fuel tank

Fuel filter clamp Nm 5

Bracket, fuel tank to frame Nm 9

Union nut (fuel-pump unit) Nm 20

Baseplate to frame
Bracket for washer fluid reservoir on frame

Bracket for washer fluid reservoir/ABS con­trol unit on frame

Model C1

Connection

Nm 9

Nm 9

17 Cooling system

Drain plug Nm 10

Vent screw Nm 9

Bracket for seat latch, right, to frame Nm 42

Bracket for seat latch, left, to frame Nm 5

00.4

Model C1

Connection

17 Cooling system

Expansion tank to frame upright Nm 3

Front frame to cross brace Nm 14

Air duct to fan shroud Nm 9

Radiator to front frame Nm 9

Fan shroud to radiator Nm 9

Air duct to front frame Nm 9

Filler bowl to front frame Nm 9

Coolant pipe clamp to frame Nm 9

Screw clamp on engine Nm Hand-tight

Bleeder screw to engine Nm 9

Model C1

Connection

18 Silencer (muffler)

Shield to holder Nm 5

Exhaust pipe to cylinder head Nm 15

Silencer to auxiliary swing arm Nm 21

Oxygen sensor to silencer Nm 23

Model C1

Connection

21 Clutch

Vent cover for variator Nm 9

Variator cover Nm 10

Driven variator (clutch drum) Nm 60

Locknut on driven variator, locking fluid Nm 50 LOCTITE 243

Model C1

Connection

24 Gearbox

Variator

Vent cover for variator Nm 9

Variator cover Nm 10

Drive variator, locking fluid Nm 60 LOCTITE 243

Cover, drive variator Nm 4

Driven variator (clutch drum) Nm 60

Locknut of driven variator, locking fluid Nm 50 LOCTITE 243

00.5

Model C1

Connection

24 Gearbox

Gearbox

Gearbox cover Nm 11

Gearbox drain plug Nm 20

Gearbox filler plug Nm 5

Model C1

Connection

31 Front forks

Fork cross brace to frame (screw stud) lock­ing fluid

Leading link to telescopic tube cross brace
locking fluid

Brake line bracket on fork cross brace Nm 5

Fork stanchion to fork cross brace Nm 52

Handlebar to fork cross brace Nm 21

Leading-link joints Nm 41

Clamp screws for leading-link joints Nm 9

Spring strut to leading link Nm 41

Ball joint to telescopic fork cross brace Nm 230

Clamp of telescopic tube to telescopic tube
cross brace

Eyebolts Nm 8

Lock to easy-lift mechanism Nm 4

Model C1

Connection

32 Steering

Nm 83 LOCTITE 243

Nm 127 LOCTITE 2701

Nm 25

ABS sensor to telescopic tube Nm 9

Combination switch Nm 4

Brake light switch Nm Hand-tight

Throttle cable Nm 8

Clamp screw for brake lever fitting Nm 9

Brake line to brake lever fitting Nm 18

Handlebar to fork cross brace Nm 21

Locknut for handlebar lever pivot pin Nm 3

00.6

Model C1

Connection

33 Final-drive unit

Top suspension strut Nm 41

Spring strut at bottom Nm 21

Auxiliary swing arm to brake caliper holder
M, screw locking fluid10

Auxiliary swing arm to brake caliper mount
M8

Model C1

Connection

34 Brakes

Brake caliper at telescopic tube Nm 41

Banjo bolt to brake caliper Nm 18

Bleed screw in brake caliper Nm 14

6-point nut to final-drive shaft
(rear wheel),

Auxiliary swing arm to brake caliper holder,
M10 bolt, with locking fluid

Auxiliary swing arm to brake caliper mount,
M8

Auxiliary swing arm to powertrain cradle Nm 21

Expansion tank cap Nm 1

use only once

Nm 60 LOCTITE 243

Nm 21

Nm 130

Nm 60 LOCTITE 243

Nm 21

Suspension strut to brake caliper carrier Nm 21

ABS sensor to brake caliper carrier Nm 9

ABS sensor to telescopic tube Nm 9

Brake disc Nm 21

ABS reluctor ring Nm 5

Baseplate to frame
Bracket for washer fluid reservoir on frame

Brake lines to ABS control unit, M12x1 Nm 18

Brake lines to ABS control unit, M10x1 Nm 18

Union, brake hose/brake line Nm 18

Bracket on frame joint Nm 5

Brake line to brake lever fitting Nm 18

All fasteners, brake line to frame Nm 5

Nm 9

00.7

Model C1

Connection

36 Wheels

Stub axle, locking fluid Nm 30

Quick-release axle clamp screws Nm 21

Brake caliper at telescopic tube Nm 41

6-point nut to final-drive shaft (rear wheel),

use only once

Nm 130

Auxiliary swing arm to brake caliper holder,
locking fluid, M10

Auxiliary swing arm to powertrain cradle, M8 Nm 21

Spring strut at bottom Nm 21

Model C1

Connection

46 Frame

Body panels to body panels Nm 2,8

Body panels to frame Nm 2,8

Lightweight foam element to frame Nm 5

Foam part to cross member Nm 5

Air plenum to rear wheel mudguard Nm 12

Roof/windscreen to cross bar Nm 5

Windscreen to bracket Nm 5

Bracket, wiper motor to roof frame Nm 5

Rear mudguard to powertrain cradle Nm 12

Air filter housing to powertrain cradle Nm 12

Nm 60 LOCTITE 243

Crash element shoulder bar to frame Nm 9

Holder, crash element to frame Nm 9

Rear frame to frame Nm 21

Suspension strut to rear frame Nm 41

Joint

Nut to frame, front left, M28 Nm 105

Screw to frame, front left, M28 Stage 1 20

Screw to frame, front left, M28 Stage 2 Back off 1/2 turn

Screw to frame, front right Nm 73

Rubber bush to frame Nm 42

Rubber bush to joint Nm 42

Powertrain cradle to joint Nm 73

Joint swinging arms to each other Nm 73

Easy-lift mechanism

Spring strut to leading link Nm 41

Articulated-lever mechanism to frame Nm 21

00.8

Model C1

Connection

46 Frame

Attachment of control cam of large hand le­ver, locking fluid

Stand to frame Nm 41

Switch (easy-lift mechanism) stand to frame Nm 8

Spring holder (easy-lift mechanism) to frame Nm 21

Bowden cable retaining bracket to frame Nm 21

Lock of Bowden cable Nm 8

Auxiliary swing arm to powertrain cradle Nm 21

Eyebolt to frame Nm 8

Shoulder bar

Seat to frame Nm 21

Head restraint to frame Nm 21

Shoulder bar, top, to frame M10 Nm 41

Shoulder bar, top, to frame M8 Nm 21

Shoulder bar, bottom, to frame M6 (clamp­ing screw)

Roof frame

Front roof bar (clamp) Nm 21

Rear roof bar (clamp) Nm 21

Nm 2 LOCTITE 243

Nm 9

Roof frame cross brace Nm 21

Mirror brackets Nm 5

Luggage system

Top bracket to frame Nm 8

Bracket to rear frame Nm 21

Top bracket to bracket Nm 21

Lock carrier Nm 5

Head restraint to frame Nm 21

Model C1

Connection

51 Equipment

Ignition lock to frame Nm 9

Seat latch Nm 9

Seat bench lock to left rear side panel Nm 3

Striker on rear storage compartment Nm 3

Lock cylinder on rear storage compartment Nm 7

Striker of storage compartment Nm 3

Lock cylinder on storage compartment Nm 7

Lock bolt for luggage rail Nm 3

00.9

Model C1

Connection

51 Equipment

Mirror bracket to frame Nm 5

Mirror to mirror bracket Nm 4

Cover on mirror arm Nm 3

Model C1

Connection

52 Seats

Seat to frame Nm 21

Seat lock Nm 9

Backrest Nm Hand-tight

Head restraint to frame Nm 21

Model C1

Connection

61 Electrical equipment

Combination switch Nm 4

Battery cable to battery Nm 3

Battery cable to starter relay Nm 3

Control current cables to starter relay Nm 0,4

Voltage regulator to frame Nm 12

BMS control unit to frame Nm 5

Wipe/wash sensor to frame Nm 3

Earth cable to frame Nm 5

Wiper arms Nm 9

Clamp, cable harness to frame Nm 5

Horn to frame Nm 8

Windscreen wiper motor to bracket Nm 5

Wiper motor bracket to roof frame Nm 5

Stationary shaft, wiper motor Nm 9

Cable to starter Nm 5

Bracket of starter relay to frame Nm 5

Bracket of wiring harness to frame Nm 5

00.10

Model C1

Connection

62 Instruments

Instrument cluster to instrument panel Nm 3

Cable clamp to instrument cluster Nm 1

Cable terminal to instrument cluster Nm 0.5

Model C1

Connection

63 Lights

Front/rear turn signal lens Nm 2

Front turn signal to fairing Nm 2

Rear turn signal to license plate holder Nm 3

Headlight subframe Nm 9

Taillamp cluster Nm 5

Model C1

Connection

65 Optional extras

Alarm system

Control unit Nm Hand-tight

Motion sensor Nm Hand-tight

Bracket/ignition coil Nm 5

Fun audio system

Volume control Nm Hand-tight

Amplifier Nm 2

Speaker front trim panel Nm 2

Speaker bracket Nm 4

Model C1

Connection

72 Seat belts

Seat belt inertia reel to frame Nm 42

Belt buckle to belt-buckle mount Nm 42

Belt-buckle mount to frame Nm 42

Secondary mudguard Nm 5

00.11

Table of service products

Item Use Order number Quantity

Lubricant

StaburagsNBU30PTM High-performance lubricating paste 07 55 9 056 992

Optimoly MP 3 High-performance lubricating paste 07 55 9 062 476

Optimoly TA High-temperature assembly paste 18 21 9 062 599

Silicone grease 300, heavy Insulation grease 07 58 9 058 193

Retinax EP2

Contact spray Contact spray 81 22 9 400 208

Chain spray Drive chain

Shell HDX2

Klüber paste 46 MR 401

Wheel, steering head and taper roller
bearing grease

Variator rollers
driven variator (pins and bearing)

against fretting corrosion
spacer, variator shaft spline, clutch
drum
crankshaft and outer disc
Shaft seal seats
Ball-bearing seats, shaft journals,
bearing shells, outer ø
Small-end bore, piston pin

83 22 9 407 845

72 60 2 316 676
72 60 2 316 667

11 00 7 660 830

11 00 7 660 831

75 g (2.65 oz)
tube

100 g (3.53 oz)
tube

100 g (3.53 oz)
tube

10 g (0.35 oz)
tube

100 g (3.53 oz)
tube

300 ml
(0.53 Imp pint/

0.32 US quart)
spray

50 ml
(0.088 Imp pint/

0.053 US quart)
spray
300 ml
(0.53 Imp pint/

0.32 US quart)
spray

400 g (14.12 oz)
tube

60 g (2.12 oz)
tube

MOLYKOTE 111

Never Seez Compound Oxygen sensor 83 23 9 407 830

Sealants

3-Bond 1110 B Surface sealant 07 58 9 056 998

3-Bond 1209 Surface sealant 07 58 9 062 376

omni VISC 1002 Surface sealant (max. 200 °C/392 °F) 07 58 1 465 170

Loctite 574 Surface sealant 81 22 9 407 301

Curil K 2 Heat-conductive sealant 81 22 9 400 243

00.12

Water pump, water pump chamber,
shaft seals

11 00 7 660 832

100 g (3.53 oz)
tube

100 g (3.53 oz)
tube

5 g (0.18 oz)
tube

30 g (1.06 oz)
tube

90 g (3.18 oz)
tube

50 ml
(0.088 Imp pint/

0.053 US quart)
tube

250 g (8.83 oz)
can

Item Use Order number Quantity

Hylomar SQ 32 M Permanently elastic sealant 81 22 9 400 339

Adhesives and retainers

100 g (3.53 oz)
tube

Loctite 648 Joint adhesive (low clearance) 07 58 9 067 732

Loctite 638 Joint adhesive (greater clearance) 07 58 9 056 030

Loctite 243 Thread retainer, medium-strength 07 58 9 056 031

Loctite 270 Thread retainer, strong 81 22 9 400 086

Loctite 2701 Thread retainer, strong 33 17 2 331 095

Loctite 454 Cyanacrylate adhesive (gel) 07 58 9 062 157

Cleaners

Brake cleaner Brake cleaner 83 11 9 407 848

Metal Polish Polish for chrome-plated parts 82 14 9 400 890

5 g (0.18 oz)
bottle

10 ml
(0.018 Imp pint/

0.010 US quart)
bottle

10 ml
(0.018 Imp pint/

0.010 US quart)
bottle

10 ml
(0.018 Imp pint/

0.010 US quart)
bottle

10 ml
(0.018 Imp pint/

0.010 US quart)
bottle

20 g (0.71 oz)
tube

600 ml
(1.056 Imp pint/

0.634 US quart)
spray

100 g (3.53 oz)
tube

Testing agents

Penetrant MR 68

Developer MR 70

Installation aids

BMW cooling spray

Crack testing agent for aluminium
housings

Crack testing agent for aluminium
housings

Cooling components before assem­bly

83 19 9 407 855

81 22 9 407 495

83 19 9 407 762

500 ml
(0.880 Imp pint/

0.528 US quart)
spray

500 ml
(0.880 Imp pint/

0.528 US quart)
spray

300 ml
(0.53 Imp pint/

0.32 US quart)
spray

00.13

00.14

00

00 Pre-delivery check

Contents

Check transport container for damage

Damage in Germany

Damage in export markets

Unpack C1

Place C1 on stand ............................................................................................................................ 19

Take the C1 from the stand ..............................................................................................................21

...................................................................................................................................... 18

Check C1 for damage

.................................................................................................................... 17

....................................................................................................... 17

..............................................................................................................23

..........................................................................17

Page

Check package contents to determine whether consignment is complete

23

Fill and charge the battery

Use BMW MoDiTeC/DIS plus to access stored error codes

Check tyre inflation pressures

Add fuel

............................................................................................................................................ 25

....................................................................................................24

..............................25

............................................................................................25

.

Operation check as final inspection

Final cleaning

Vehicle delivery

............................................................................................................................... 26

............................................................................................................................ 26

................................................................................25

00.15

00.16

00

Check transport container for dam­age

Inspect the transport container immediately for

•

damage as soon as the C1 is delivered, remem­bering to check for collateral damage if indicated

Damage in Germany

Record the damage on the consignment waybill

•

Read transport damage information sheet

•

Inform supplier (freight expediter, rail, etc.) and

•

Bavaria Wirtschaftsagentur GmbH
Abteilung ZW - 12
80788 München
Tel. [phone]
Fax. [phone]
immediately

Damage in export markets

Record damage on the consignment waybill

•

National response arrangements apply

•

Submit questions to:
Bavaria Wirtschaftsagentur GmbH
Abteilung ZW - 12
80788 München
Tel. [phone]
Fax. [phone]
Inform supplier (freight expediter, etc.) immedi-

•

ately

00.17

Unpack C1

Open shipping container at strap holes (enlarged

•

openings) on left and right sides
Remove any enclosed packages

•

–Luggage rack

Cut open along the line indicated (follows path of

•

strap)
Dismantle shipping container

•

e

Attention:

Loosen straps without yet removing!

Loosen straps

•

C1000340

C1000350

00.18

e

Attention:

Ensure that it will be possible to fold out the stand!

Place C1 on stand

L

Note:

Note instruction plate on instrument trim!

C1000360

L

Note:

The easy-lift mechanism has overload protection.
Fold out the stand with foot if necessary!

1

C1000370

Push up long lever (1) on easy-lift mechanism

•

until it reaches the end of its travel
– The front wheel lifts clear of the ground
– Keep a firm grip on the lever

Slowly move the long lever (1) back until the de-

•

tent engages

Check to verify that the C1 is standing securely

•

2

1

C100BA56

e

Attention:

Excessive strain can damage the easy-lift mecha­nism!

Hold C1 vertical

•

Centre the handlebar

•

Pull up short lever (2) on easy-lift mechanism

•

– The stand extends

00.19

Release and remove straps

•

C1000390

Remove cross member (arrow, shipping brace)

•

C1000380

00.20

e

Attention:

Use ramp to avoid damage.

Use ramp from motorcycle hoist, etc.

•

e

Attention:

Clear away any nails lying on the bottom of the ship­ping container or the shop floor.

C1000400

Take the C1 from the stand

e

Attention:

The stand must be folded all the way back before
the vehicle is rolled down!
Excessive strain can damage the easy-lift mecha­nism!

00.21

Check that the stand is fully retracted

•

L

1

Note:

The easy-lift mechanism has overload protection. If
necessary, use your foot to retract the stand.

Push C1 off the pallet backwards

•

e

Attention:

Make sure the surface under the vehicle is level and
firm!
Do not park the C1 on slopes of more than 6°/12%,
as the stand may fail to provide secure support.

C1000370

Remove weight from vehicle

•

Release long lever (1) from the detent mecha-

•

nism by

– first moving the lever (1) on the easy-lift mecha-

nism all the way forward and up, and then slowly

pushing it downward
– Keep a firm grip on the lever
– The front wheel is lowered to the ground

2

1

C1000410

Hold C1 vertical

•

Push short lever (2) on easy-lift mechanism

•

downward
– The stand retracts

En sure t hat the lo ng lev er (1) is locked at the bot-

•

tom

Place C1 on stand (a 00.19)

•

e

Attention:

Do not cut adhesive tape - can damage shoulder
bar!

C1000420

Remove protective wrap from shoulder bar

•

Dispose of the shipping materials through eco-

•

logically sound channels, refer to bikebox

00.22

Check C1 for damage

Record and problems

•

"Early warning card" to

•

BMW Motorrad, UX-VS-1
Fax number 089/382 332 20

[phone]

Rectify problems

•

Order any necessary parts via the electronic

•

parts catalogue
Submit expense claims through GW system

•

(Stage 4) Diagnosis codes:
– Missing parts 10 01 00 00 00
– Damaged parts 10 02 00 00 00
– Incorrect parts delivery 10 03 00 00 00
If required components are not available through the
electronic parts catalogue, please contact the
C1 support staff at UX-VS-2
Phone: [phone]

[phone]

Check package contents to deter­mine whether consignment is com­plete

Optional equipment

•

Open rear storage compartment

•

Check contents of enclosed package:

•

On-board tool kit:

•

– Screwdriver with dual insert
– Pair of universal pliers
– Spark plug spanner
–1 angled Allen wrench

Torx T25

– Roadside assistance kit

Vehicle documentation

•

– Rider's Manual
– Service and technology manual
– Remove directory of European dealers from the

factory equipment package and enclose

– BMW roadside assistance service sticker (do-

mestic only)
Vehicle keys, 2

•

Please submit urgent queries and questions con­cerning technical issues to the C1 support staff at
UX-VS-2
Phone: [phone]

[phone]

00.23

C1000430

Fill and charge the battery

Open cover of rear storage compartment

•

– Remove battery cover
– Remove the battery

a

....................................................See Group 61

d

Warning:

Battery acid is extremely caustic.
Protect your eyes, face, hands, clothing and the
paintwork!

Pull off battery vent hose

•

Remove battery

•

Fill battery with electrolyte, continuing until it

•

reaches upper graduation (arrow)
Allow the battery to stand for at least an hour

•

Shake the battery slightly to allow the remaining

•

air bubbles to escape
Refill to upper graduation as necessary

•

Recharge the battery or allow to stand for

•

24 hours

Charge current (amps)

.....................................10 % of rated capacity (Ah)

Use distilled water to top up the electrolyte, con-

•

tinuing until it reaches the upper graduation
Make a note of the charging date on the battery

•

e

Attention:

Start by tightening the battery' positive terminal,
then proceed to the negative side!

Apply acid-resistant grease to the bettary termi-

•

nals
Installing the battery

•

Install battery cover

•

Close rear storage compartment

•

Fluids and lubricants:

Acid-resistant grease ............................from Bosch

X

Torque specification:

Battery cable to battery terminals................... 3 Nm

00.24

Use BMW MoDiTeC/DIS plus to access stored error codes

C1000010

Open seat by inserting ignition key in lock at the

•

left rear

Release backrest mount and remove backrest

•

Connect diagnosis unit to diagnosis plug

•

Access stored error codes

•

Carry out any repair operations indicated

•

Install backrest

•

Check tyre inflation pressures

Check/correct tyre inflation pressures

•

Tyre inflation pressures:

One-up.............................. Front 1.9 bar (27.56 psi)

.......................................... Rear 2.1 bar (30.46 psi)

Full load ............................ Front 2.1 bar (30.46 psi)

.......................................... Rear 2.4 bar (34.81 psi)

Add fuel

Open the seat

•

Pour in fuel

•

Operation check as final inspection

C1000040

Check engine oil

•

Safety belt release mechanism

•

Clutch engagement speed

•

Steering

•

Front and rear brakes

•

Check lights and signalling equipment:

•

– Front and rear parking lamps
– Instrument illumination
– Headlamp, high beam, headlamp flasher
– Brake lamp (actuation of front and rear brakes)
– Left/right turn signals
–Horn
– Indicator and warning lights
– Instruments

Check any optional equipment to confirm that it

•

is operational, check ABS, carry out driving test.
When vehicle is ridden for at least 10 seconds at
over 30 km/h (19 miles/h) the ABS warning lamp
will come on if there any problems in the ABS
Conduct road test as required

•

Confirm delivery in service and technology man-

•

ual
Respond to problems by refering to "Checking

•

C1 for defects"

00.25

Final cleaning

Vehicle delivery

Cleaning the C1

•

L

Note:

Do not use steam cleaners or high-pressure spray
wands. High water pressure can lead to damage af­fecting seals as well as the hydraulic and electrical
systems.

L

Note:

To ensure optimal orientation of every licence plate,
the licence plate holder is not equipped with sock­ets!

To promote optimal levels of safety and foster satis­faction, the customer should be acquainted with the
C1 as part of the delivery process.

Show/explain the following to the customer:

•

– On-board literature and its storage location
– Owner's manual for description of functions
– Service and technology for service activities on

the C1
– On-board tools and their location
– Operation of the easy-lift mechanism
– Safety belt use - starting lockout
– Central belt release mechanism
– Starting with rear brake engaged - clutch en-

gagement speed
– Windscreen wiper and washer fluid refill cap lo-

cation
– Oil and brake fluid level checks
– Mirror adjustment
– Controls
– Instruments and warning lamps
– Any optional equipment

The customer must be informed of the following:

•

– Break-in information and service intervals
–Helmet laws
–Safety check

00.26

00

00 Maintenance

Contents

Maintenance intervals

1,000 km/600 miles Inspection .........................................................................................................31

BMW Service ...................................................................................................................................31

BMW Inspection ...............................................................................................................................31

BMW Annual Service ........................................................................................................................31

Reading out BMW MoDiTeC/DIS and error codes stored in ECU

(Inspections I, II, III and IV) ................................................................................................................31

Engine oil change

(Inspections I, II, III and IV) ................................................................................................................32

Drain engine oil and clean magnetic plug .........................................................................................32

Clean oil filter screen ........................................................................................................................32

Replace oil filter element .................................................................................................................. 32

Refill engine with oil ..........................................................................................................................33

Gearbox oil change

(Inspection III, IV) every 30,000 km/18,000 miles or every 3 years .................................................... 33

Checking coolant

(Inspections I and III) ........................................................................................................................34

Adding coolant .................................................................................................................................34

.............................................................................................................31

...................31

....................................................................................................................... 32

...................................................................................................................33

....................................................................................................................... 34

Page

Change coolant

(Inspection IV, every 2 years) .............................................................................................................35

Drain coolant ....................................................................................................................................35

Draining expansion tank ...................................................................................................................35

Adding coolant .................................................................................................................................35

Checking valve clearances

(Inspections I, II and III) .....................................................................................................................36

Swivel out powertrain cradle

Checking valve clearances

Adjusting valve clearances

Replace spark plug

(Inspections II and III) ........................................................................................................................42

Replacing air cleaner element

(Inspections II and III) ........................................................................................................................43

Empty drain pipe from intake-air plenum chamber

(Inspection IV) ................................................................................................................................... 43

Checking brake lines

(Inspections II and III) ........................................................................................................................44

Checking brake lines ........................................................................................................................ 44

........................................................................................................................... 35

...................................................................................................36

....................................................................................................36

.......................................................................................................38

.......................................................................................................39

...................................................................................................................42

............................................................................................43

................................................. 43

................................................................................................................44

Checking brake system operation and inspect for leaks

(Inspections II and III) ........................................................................................................................ 44

.....................................44

00.27

Contents

Page

Checking brake fluid level

(Inspections I, II and III) .....................................................................................................................44

Checking fluid level in the closed brake fluid reservoir

Checking fluid level in the open brake fluid reservoir

Checking brake pads and discs for wear/replacing

(Inspections II and III) ........................................................................................................................46

Checking brake pads for wear

Front brake pads .............................................................................................................................. 46

Rear brake pads ...............................................................................................................................46

Replacing brake pads

Front brake .......................................................................................................................................47

Rear brake ........................................................................................................................................48

.................................................................................................................47

Checking the brake discs

Replacing brake fluid

(Inspection IV) ................................................................................................................................... 50

Front brake

Drawing off brake fluid/forcing back brake pistons ...........................................................................50

Bleed the front brake circuit .............................................................................................................51

....................................................................................................................................... 50

.....................................................................................................44

................................................ 44

................................................... 45

............................................... 46

................................................................................................46

.........................................................................................................49

...............................................................................................................50

Rear brake

Drawing off brake fluid/forcing back brake pistons ...........................................................................51

Bleeding rear brake circuit ................................................................................................................ 52

Variator drive belt replacement

(Inspections II and III) ........................................................................................................................52

Check belt

Checking clutch lining

(Inspection III) ...................................................................................................................................54

Clean variator filter screen

(Inspections II and III) ........................................................................................................................54

Drive variator

Remove drive variator

Check, clean and grease drive variator (lubricated version)

(Inspection II, III) (lubricated version) .................................................................................................55

Check and clean drive variator (unlubricated version)

(Inspection II, III) (unlubricated version) ............................................................................................. 57

........................................................................................................................................ 51

..........................................................................................52

........................................................................................................................................ 53

.............................................................................................................54

....................................................................................................54

................................................................................................................................. 55

.................................................................................................................55

......................................55

................................................. 57

Replacing complete drive variator

(Inspection II) every 22,500 km (13,500 miles) – lubricated version only ...........................................58

Checking wheel bearing float

(Inspection III) ...................................................................................................................................59

00.28

....................................................................................58

..............................................................................................59

Contents

Page

Check to ensure that leading link bearing has zero play

(Inspection I, IV) ................................................................................................................................60

Checking steering bearing play ........................................................................................................60

Check battery electrolyte level - add distilled water if necessary

(Inspection IV) ................................................................................................................................... 60

Checking battery electrolyte level

Adding distilled water .......................................................................................................................61

Clean/grease battery terminals if necessary

(Inspection IV) ................................................................................................................................... 61

Checking Bowden cables

(Inspections III and IV) ......................................................................................................................61

......................................................................................................61

Checking windscreen washer

(Inspections I, II and III) .....................................................................................................................62

Check windscreen wiper

(Inspections II, III and IV) ...................................................................................................................62

Checking safety elements

(Inspections I, II, III and IV) ................................................................................................................62

.......................................................................................................62

.....................................................................................................62

Check Bowden cable for central seat-belt release

..........................................................................................60

.............................................................. 61

.............................................................................................62

........................................................ 62

.....................................60

..................60

Check belt straps and belt buckles

Check inertia reels

....................................................................................................................... 62

......................................................................................62

Check inertia-reel's detent mechanism to ensure that it engages correctly

Examine crash elements

(Inspections I, II, III and IV) ................................................................................................................63

Check shoulder bar and deformation element

(Inspections I, II, III and IV) ................................................................................................................63

Measure shoulder bar

Replacing fuel filter

(Inspection II) every 37,500 km (22,500 miles) .................................................................................. 63

...................................................................................................................63

........................................................................................................63

.......................................................... 63

.................................................................................................................63

Replacing boot in brake-control assembly (master cylinder), only
with optional ABS

(Inspection III) every 30,000 km (18,000 miles ) ................................................................................. 64

Check mounts

(Inspection I) .....................................................................................................................................65

Final inspection with road safety and operation check

(Inspections II, III and IV) ................................................................................................................... 65

Tyre tread depth (recommended minimum) .......................................................................................65

Tyre pressures (tyres cold) ................................................................................................................65

Roadworthiness check .....................................................................................................................65

....................................................................................................................... 64

.............................................................................................................................. 65

........................................ 65

......62

00.29

00.30

00

Maintenance intervals

1,000 km/600 miles Inspection

BMW Break-in Inspection after the initial 1,000 km/
600 miles

BMW Service

At the end of the first 7,500 km/4,500 miles
and then at intervals of 15,000 km/9,000 miles,(at
22,500 km, 37,500 km…/13,500 miles,
22,500 miles… )

BMW Inspection

At the end of the first 15,000 km/9,000 miles
and then at intervals of additional 15,000 km/
9,000 miles,(at 30,000 km, 45,000 km…/18,000 miles,
27,000 miles…)

BMW Annual Service

Although many service operations are scheduled
according to milage, many procedures (such as
brake fluid changes) should be carried out at least
once a year, regardless of elapsed milage.
If these operations are not performed in the course
of a standard, milage-based Service or Inspection,
an extra visit for an Annual Service will be required.

The codes for service and maintenance intervals in
this repair manual are as follows:

Reading out BMW MoDiTeC/DIS and error codes stored in ECU

(Inspections I, II, III and IV)

Open the seat

•

Remove the backrest

•

C1000010

Connect

•

ble to diagnostic interface (arrow)

L

Note:

Follow the instructions in the diagnosis program.

MoDiTeC/DIS plus diagnosis ca-

BMW

– BMW Inspection at 1,000 km/600 miles ............

– BMW Maintenance Service every

7,500 km/4,500 miles .......................................

– BMW Inspection every 15,000 km/9,000 miles

– BMW Annual Service ......................................

Operations specified for extended-milage vehi­cles:

a

Replacement of complete drive variator (

a

............................. Refer to Assembly Group 24

.......................................... for more information

Vehicles with ABS: replace handbrake fittings (rub­ber diaphragm on brake master cylinder) (

a

............................. Refer to Assembly Group 32

.......................................... for more information

Replace fuel filter (a00.63)

a

............................. Refer to Assembly Group 16

.......................................... for more information

00.58)

a

00.64)

I

II
III
IV

00.31

Engine oil change

(Inspections I, II, III and IV)

Drain engine oil and clean magnetic plug

Clean oil filter screen

L

Note:

Drain the engine oil only after the engine has
warmed to normal operating temperature!

e

Attention:

Observe all safety precautions when allowing an in­ternal-combustion engine to run in an enclosed ar­ea!

1

Unscrew oil filter screen bolt (2)

•

Clean oil filter screen

•

Replace oil filter element

2

C1000022

11 7 661

Unscrew magentic oil drain plug (1)

•

Clean magnet

•

C1000022

Secure oil guard

•

haust
Unscrew oil filter cover bolts (arrows)

•

BMW No. 11 7 661

C1000330

to the ex-

00.32

BMW recommends Castrol

Fluids and lubricants:

Engine oil ................................ 1.0 l/1.76 Imp pints

Brand- name HD oi l, AP I cl a ssi fica tion SF, S G or S H;
suffix letters CD or CE are approved; alternatively,
brand-name HD oil with CCMC classification G4 or
G5; suffix PD2 is permitted.

X

Tightening torque:

Oil filter cover ............................................... 10 Nm

Magnetic oil drain plug ................................. 20 Nm

Oil filter screen attachment bolt.................... 30 Nm

Replace oil filter element

•

Refill engine with oil

L

Note:

Replace drain plug seal rings!

C1000030

C1000040

Gearbox oil change

(Inspection III, IV) every 30,000 km/18,000 miles
or every 3 years

1

Unscrew oil drain plug (1)

•

Pour gearbox oil in filler opening (2)

•

Fluids and lubricants:

GL 4 gear lubricant ................ 0.09 l/0.16 Imp pints

2

C1000500

Add engine oil through oil filler neck

•

Add oil up to the MAX mark on the dipstick

•

Run the engine briefly, then switch it off and

•

check oil level again: add oil if necessary
Check coolant level and top up as required

•

00.33

Checking coolant

Adding coolant

(Inspections I and III)

max

min

C1000050

L

Note:

Check coolant level only with the engine cold!

Open the seat and check the coolant level

•

Maximum level ............................................

Minimum level ..............................................

"max"

"min"

– Remove the backrest

1

2

C1000060

Remove cap (1) from expansion tank (2)

•

e

Attention:

Add or refill coolant only when engine is cold. Add
coolant to expansion tank only if a small quantity has
been lost. Otherwise refill with coolant (a17.15).

Reinstall cap (1)

•

00.34

Change coolant

(Inspection IV, every 2 years)

Drain coolant

– Remove front fairing panel
– Loosen radiator cap

C1000071

Adding coolant

Pour coolant into filler neck

•

C1170290

Slip hose (arrow) over screw head

•

Remove drain plug

•

Drain coolant

•

L

Note:

Replace drain plug seal!

Tighten drain plug

•

X

Torque specification:

Drain plug..................................................... 10 Nm

Draining expansion tank

L

Note:

If powerplant cradle is pivoted expansion tank may
be accessed under lock fitting. Alternatively, draw
off coolant with a syringe or similar.

1

C1000080

Open vent screw (1) in cylinder head to bleed air

•

from system, reclosing only after coolant starts
to emerge
To top up coolant in expansion tank

•

Run the engine briefly, then stop it, recheck cool-

•

ant level and top up if necessary

Capacities:

Cooling system ...................... 1.25 l/2.20 Imp pints

Expansion tank ........................ 0.2 l/0.35 Imp pints

e

Attention:

Use only nitrite-free extended-duty antifreeze with
corrosion inhibitor!

Mixture ratio:

Water .............................................................. 50%

Antifreeze.........................................................50%

Protection down to .............................—25 °C/77 °F

00.35

Checking valve clearances

(Inspections I, II and III)

Swivel out powertrain cradle

Secure front wheel

•

Remove wiring from clip (arrow):

•

- Alternator

- Ignition unit

C1000090

Remove wiring from clip:

•

- Injector

- Air temperature sensor

- Idle actuator

- Coolant temperature sensor in cylinder head

C1000110

Open the seat

•

C1000100

Release clip and disconnect plug from oxygen

•

sensor (arrow)

C1000120

Release coolant hose from clamp at injector and

•

on variator cover bracket (arrow)

00.36

C1000130

e

Attention:

To avoid stretching hoses and lines, do not swivel
the powertrain cradle more than 20°!

Lift C1 no further than stop: powertrain cradle

•

swivels down

When installing:

Install the cylinder head cover before swiveling

•

the powertrain cradle back into place

e

Attention:

Ensure that gasket and cover are free of oil!

Remove hose from bracket on intake-air plenum

•

chamber (arrow)

33 1 531

00 1 580

00 1 570

C1000140

Position vehicle jack

•

tachment
Raise the vehicle slightly

•

Install fixture,

•

spring strut and powertrain cradle
Remove lower end of right spring strut from

•

brake caliper holder

BMW No. 00 1 580

BMW No. 33 1 531,

BMW No. 00 1 570

at separation point

between left

with at-

Installing cylinder head cover

•

e

Attention:

When lowering note positions of struts and intake­air plenum chamber!

L

Note:

Ensure that the detent engages to secure the long
lever on the easy-lift mechanism. If necessary, move
the lever to the drive position first, and then move it
to the park position.

X

Tightening torque:

Cylinder head cover ..................................... 10 Nm

Strut, lower .................................................. 21 Nm

00.37

Checking valve clearances

– Remove left and right service covers
– Swivel out powerplant cradle

17 5 500

1

Open hose clamp (arrow) with pliers

•

BMW No. 17 5 500

Unscrew cylinder head cover bolts (1)

•

C1000150

C1111001C1000170

Measure valve clearance using single feeler

•

gauge blade
Record the valve clearances

•

and adjust valve clearance as indicated (replace

•

valve lifters)

Specified clearances:

C1000160

Watch throttle (arrow)

•

Remove spark plug

•

Use camshafts to rotate engine until the lobes

•

are pointing outward

IV left
mm (in)

0.05

Spec.
clearance

Clearance,
measured
(used)

Difference

Inlet valve clearance........................0.05…0.09 mm

............................................ (0.00197…0.00354 in)

Exhaust valve clearance..................0.20…0.29 mm

............................................ (0.00787…0.01147 in)

(0.00197)

0.09
(0.00354)

0.15
(0.00590)

0.01
(0.00039)

IV right
mm (in)

0.05
(0.00197)

0.09
(0.00354)

EV left
mm (in)

0.20
(0.00787)

0.29
(0.01147)

0.15
(0.00590)

-0.05
(-0.00197)

EV right
mm (in)

0.20
(0.00787)

0.29
(0.01147)

00.38

Adjusting valve clearances

To foster enhanced clarity, some of the illustrations
show components with the powerplant cradle re­moved

– Swivel out powerplant cradle
– Checking valve clearances

C1130010

Loosen hose clamp (arrow) on intake-air plenum

•

chamber

11 7 651

C1000220

Remove Allen bolt adjacent to starter and use

•

special bolt,

L

Note:

Because the round cover plate can rotate against
the gear, the TDC mark should always be made on
the gear itself - not on the cover plate

BMW No. 11 7 651,

to lock at TDC

C1000200

L

Note:

Watch for dirt and contamination around the starter/
threaded plug (arrow) - no contamination in engine!

C1000180

Use a coloured marker to mark TDC (arrow) on

•

the inlet camshaft's sprocket

00.39

Release chain tensioner bolt (arrow)

•

C1000231

L

Note:

Watch bolt length and take care to install in correct
positions,
lettering is to the outside, use coloured marker to
identify end as necessary!

C1000190

Detach mounts (arrows) from chain guide and re-

•

move

C1110910

Press chain tensioner to the outside using chain

•

tensioning rail

L

Note:

The bolts on the chain guide mechanism are se­cured with thread-locking compound!

L

Note:

The camshafts can also be removed and installed
with the sprockets in place!

L

Note:

The camshaft sprocket is secured with locking com­pound!

Undo bolts and remove camshaft sprokets

•

L

Note:

Make sure that the timing chain does not drop into
the housing. Use a retainer to keep timing chain ten­sioned at all times!

Secure the timing chain to prevent it from falling

•

00.40

L

Note:

Note the length of the bolts used to attach the cam­shaft bearing cap!

C1000232

Subtract negative difference of bucket (old)

•

Add positive difference of bucket (old)

•

Note sizes of available bucket tappets

•

L

Note:

The bucket tappets are available in sizes ranging
from 2.50 mm (0.09842 in) to 3.20 mm (0.12598 in)
in 5/100ths graduations.
Should it prove impossible to adjust the valve clear­ance with the smallest bucket tappet (2.50 mm/

0.09842 in) the cylinder head will have to be re-

a

placed (
If it is not possible to adjust the valve clearance with
the largest bucket tappet (3.20 mm/0.12598 in) the
valve seat will have to be reground (a11.30).

When installing:

While installation is basically a reversal of the re-

•

moval process, careful attention should be di­rected toward the following operations:

11.40).

Remove 8 bolts

•

Remove camshaft bearing cap

•

Removing camshafts

•

Remove camshaft bearing seat

•

Remove the tappet

•

Record the figures on the bottoms of the tappets

•

Sample calculation:

Spec.
clearance

Clearance,
measured
(used)

Difference

Bucket,
measured
(used)

Bucket
specifica­tion (new)

Bucket,
measured
(new)

Clearance
specifica­tion (new)

IV left
mm (in)

0.05
(0.00197)

0.14
(0.00551)

0.15
(0.00590)

0.01
(0.00039)

2.80

(0.11023)

2.81
(0.11062)

2.85
(0.11220)

0.10
(0.00394)

IV right
mm (in)

0.05
(0.00197)

0.14
(0.00551)

EV left
mm (in)

0.20
(0.00787)

0.29
(0.01147)

0.15
(0.00590)

-0.05
(-0.00197)

2.80

(0.11023)

2.75
(0.10826)

2.75
(0.10826)

0.20
(0.00787)

EV right
mm (in)

0.20
(0.00787)

0.29
(0.01147)

e

Attention:

The grooves in the bearing caps are oil passages!
Note the lengths of the camshaft bearing cap bolts!

C1110111

e

Attention:

Align bearing caps, make sure that bearing caps
and bearing seats are correctly aligned. Run a finger
along the joint to check alignment!

Remove traces of Loctite from threads of cam-

•

shafts and chain guide
Coat threads of fasteners for chain guide and

•

camshaft gear with Loctite
The inlet camshaft bears a punch mark (arrow) as

•

identification
Make sure that the camshafts turn easily and

•

smoothly

Clearance,
measured
(new)

00.41

L

Note:

Always renew the screw plug's sealing ring!

Install chain tensioner (a11.33)

•

e

Attention:

Remove TDC set bolt,

BMW No. 11 7 651.

Replace spark plug

(Inspections II and III)

– Remove left service cover

Turn the engine over several times by hand

•

Check valve clearance and adjust as necessary

•

L

Note:

Install cover seal, ensuring that it and groove in cyl­inder head cover are free of oil!

Install the cylinder head cover before installing

•

the powertrain cradle

e

Attention:

When lowering note the positions of the spring
struts!

L

Note:

Make sure the long lever of the easy-lift mechanism
engages. If necessary, move the lever to the drive
position first, and then move it to the park position!

Fluids and lubricants:

Guide rail............................................... Loctite 243

Camshaft sprocket ................................ Loctite 243

12 3 531

C1120030

Disconnect spark plug cap

•

Use spark-plug wrench,

•

remove spark plug

X

Torque specification:

Spark plugs.................................................. 15 Nm

Fluids and lubricants:

Spark plug .........................................NGK CR 8EB

BMW No. 12 3 531,

to

X

Torque specification:

Guide rail attachment ................................... 10 Nm

Camshaft sprockets .................................... 30 Nm

Camshaft bearing cap bolt ........................... 10 Nm

TDC bolt socket plug ................................... 15 Nm

Chain tensioner plug .................................... 35 Nm

Lower strut mount ........................................ 21 Nm

00.42

Replacing air cleaner element

(Inspections II and III)

1

Empty drain pipe from intake-air plenum chamber

(Inspection IV)

Empty the drain pipe from the air cleaner housing

•

C1130010

Remove fasteners (1) securing cover to air filter

•

housing
Replace air filter element

•

C1000130

Remove plug (arrow) and allow oil which has

•

drained out to escape
Assembly is the reverse of the dismantling pro-

•

cedure

00.43

Checking brake lines

Turn the handlebars at full left-hand lock

•

(Inspections II and III)

e

Attention:

Refer to and observe the precautions for handling
brake fluid!

Check brake calipers, unions and lines on brake

•

system for correct operation, leaks, damage and
incorrect positioning; repair or replace as neces­sary
Check the brake fluid level and top up if neces-

•

sary

Checking brake lines

Examine all brake lines for damage and correct

•

routing

Checking brake system operation and inspect for leaks

(Inspections II and III)

Check condition and routing of all lines and con-

•

nections

Checking brake fluid level

(Inspections I, II and III)

Checking fluid level in the closed 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
basically the same.

L

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 accom­modate lining wear.
A level below MIN indicates the possibility of other
system defects!

C1340430

Check the level of brake fluid through the sight

•

glass

Minimum level (arrow)

............. slightly above the centre of the sight glass

wear limit with worn brake pads

d

Warning:

The brake fluid level must never be allowed to fall
below the MIN mark (arrow) used to identify the ab­solute minimum level. Otherwise, there is a danger
that air will be drawn into the brake system during
operation!

e

Attention:

The fluid level in the brake fluid reservoir must be at
the “MAX” mark with new brake pads. It is not pos­sible to verify that the fluid is at maximum level
through the sight glass. For details on the correct
procedure see

brake fluid reservoir!

00.44

Checking fluid level in the open

Checking fluid level in 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
basically the same.

e

Attention:

Do not allow brake fluid to come into contact with
painted parts of the motorcycle - brake fluid attacks
paintwork!

L

Note:

Do not remove the reservoir cap unless the handle­bar is turned all the way to the right!

Turn the handlebar all the way to the right

•

Secure the handlebar in the full lock position

•

1

MAX

C1340450

Specification:

Specified level with new pads

...................... Upper edge on inside of sight glass

e

Attention:

When adding brake fluid, do not allow it to enter the
holes for the reservoir cap screws!

If the brake fluid level does not come up to the

•

top of the sight glass with new brake pads in­stalled top up the fluid level and, if necessary,
check the brake system for leaks

Remove reservoir cap (1) with diaphragm

•

C1340440

When installing:

While installation is basically a reversal of the re-

•

moval process, careful attention should be di­rected toward the following operations:

L

Note:

Wipe the rim of the reservoir, the rubber boot and
the cover to remove brake fluid, and carefully reas­semble the components!

Hand-tighten cap on reservoir

•

Check operation of the brake system

•

Operating fluid:

Brake fluid.....................................................DOT 4

00.45

Checking brake pads and discs for wear/replacing

(Inspections II and III)

Checking brake pads for wear

d

Warning:

Never allow brake pads to wear below the minimum
specified thickness!
Always replace pads as a complete set!

Front brake pads

Rear brake pads

C1340360

Visually inspect the brake pads from behind

•

– Replace the brake pads if a wear mark (arrows) is

no longer clearly visible

C1340340

Visually inspect the brake pads from behind and

•

below

– Replace the brake pads if a wear mark (arrows) is

no longer clearly visible

MIN

C1340350

Minimum pad thickness

The brake pads have a clearly visible chamfer (ar­row) as a wear indicator

MIN

C1340370

Minimum pad thickness

The brake pads have a clearly visible chamfer (ar­row) as wear indicator

00.46

Replacing brake pads

Front brake

e

Attention:

Never separate the two sections of the brake cali­per!

Firmly press the brake caliper against the brake

•

disc in order to force back the brake pads and
pistons

L

Note:

If the brake pads/pistons cannot be forced back in
this way, this can indicate a defect in the brake sys­tem!

21

C1340380

Remove the cotter pin (2) from the dowel pin (1)

•

1

34 1 541

C1340390

Remove dowel pin (1) with drift punch or pliers,

•

BMW No. 34 1 541

Remove the brake pads.

•

When installing:

While installation is basically a reversal of the re-

•

moval process, careful attention should be di­rected toward the following:

e

Attention:

Do not damage the brake pads when installing!

Checking operation of the brake system

•

e

Attention:

The fluid level in the brake fluid reservoir must be at
the “MAX” mark after the brake pads have been
changed. It is not possible to determine whether the
fluid is at the specified maximum level using the
sight glass. For details on the correct procedure see

Checking fluid level in the open brake fluid reser­voir!

00.47

Rear brake

e

Attention:

Never separate the brake caliper sections!

1

C1340400

Detach the lower end of the strut (1) and tie it up

•

out of the way

e

Attention:

Avoid scratching or otherwise damaging the wheel
rim, mask off brake caliper if necessary!

L

Note:

If the brake pads/pistons cannot be forced back in
this way, this may indicate a defect in the brake sys­tem!

34 1 570

1

2

C1340411

Remove the cotter pin (1) from dowel pin (2)

•

Remove dowel pin (2) with extractor,

•

BMW No. 34 1 570

Pull out the brake pads toward the rear

•

1

2

C1340020

Firmly press the brake caliper against the brake

•

disc in order to force back the brake pads and
pistons

1

Pull support plate (1) back and up

•

C1340470

00.48

1

C1340480

Remove support plate (1) to the inside

•

When installing:

While installation is basically a reversal of the re-

•

moval process, careful attention should be di­rected toward the following operations:

e

Attention:

Always replace the backplate!
Ensure that the backplate seats correctly!
Take care to avoid damaging brake pads when in­stalling!

Checking the brake discs

Carefully check the brake discs for cracking,

•

damage, deformation and scoring

C1340420

Measure the thickness of the brake discs at sev-

•

eral points with a caliper gauge

Wear data:

Front brake discs ..................... 4.0 mm/0.15748 in

Rear brake disc........................ 4.0 mm/0.15748 in

Install new backplate

•

Use a long-nosed punch to install the dowel pin

•

Check the operation of the brake system

•

e

Attention:

The fluid level in the brake fluid reservoir must be at
the “MAX” mark after the brake pads have been
changed. It is not possible to determine whether the
brake fluid is at the specified maximum level through
the sight glass. For details on the correct procedure
see

Checking fluid level in the open brake fluid

reservoir!

00.49

Replacing brake fluid

(Inspection IV)

e

Attention:

Protect trim panels against contact with brake fluid!

e

Attention:

Observe all precautions for handling brake fluid!

e

Attention:

To ensure continued safety the brake fluid must be
changed annually!
The brakes must be bled and checked to ensure
that they are in full working order!

Vehicles with ABS

e

Attention:

On vehicles with
erations in the repair manual must be supplemented
by bleeding operations performed using the

MoDiTeC/DIS plus with the ABS control units

BMW

toolbox.
There is a danger that residual air will remain in the
ABS control circuits if
not used.

Connect a commercially-available suction device

•

to the brake fluid bleed screws on the caliper
Force the pistons all the way back into the brake

•

calipers

L

Note:

This description applies to the brake filling and
bleeding units that operate using suction at the
bleed fitting on the brake caliper.
If other devices are used, comply with their manu­facturers' instructions!

the brake system service op-

ABS

MoDiTeC/DIS plus is

BMW

Front brake

e

Attention:

Do not allow brake fluid to come into contact with
painted parts of the motorcycle - brake fluid attacks
paint!

Drawing off brake fluid/forcing back brake pis­tons

Firmly press the brake caliper against the brake

•

disc in order to force back the brake pads and
pistons

L

Note:

If the brake pads/pistons cannot be forced back in
this way, there may be some defect in the brake sys­tem!

Connect the brake bleeding device to the bleed

•

screw on the brake caliper
Open the bleed screw by half a turn

•

Draw off brake fluid from the front brake circuit

•

When installing:

Installation is the reverse of the removal proce-

•

dure

e

Attention:

On vehicles with
described in the repair manual must be supplement­ed by bleeding operations using the

MoDiTeC/DIS plus with the ABS control unit

BMW

toolbox.
Failure to use the
a hazard of residual air remaining in the ABS control
circuits.

Add brake fluid until it reaches the top of the

•

sight glass
Bleed the front brake circuit

•

Check the operation of the brake system

•

the brake service operations

ABS

MoDiTeC/DIS plus results in

BMW

00.50

Bleed the front brake circuit

e

Attention:

On vehicles with
described in the repair manual must be supplement­ed by bleeding operations using the

MoDiTeC/DIS plus with the ABS control unit

BMW

toolbox.
Failure to use the
a hazard of residual air remaining in the ABS control
circuits.

– Add brake fluid until it reaches the top of the

sight glass
Connect the brake bleeding device to the bleed

•

screw on the brake caliper

Bleed vehicle with

[ABS]

•

•

e

Brake fluid level must not drop below the MIN mark
during the bleeding process, otherwise air will be
drawn into the brake system. Bleed the system
again if this happens!

MoDiTeC/DIS plus

BMW

Open the bleed screw by half a turn

Attention:

the brake service operations

ABS

MoDiTeC/DIS plus results in

BMW

Rear brake

e

Attention:

Do not allow brake fluid to come into contact with
painted parts of the motorcycle - brake fluid attacks
paint!

Drawing off brake fluid/forcing back brake pis­tons

e

Attention:

Avoid damaging or scratching the brake caliper;
mask it off if necessary!

Continue to extract brake fluid until it emerges

•

clear and free of air bubbles
Tighten the bleed screw

•

Check the operation of the brake system

•

Operating fluid:

Brake fluid .....................................................DOT 4

X

Torque specification:

Bleed screw ................................................. 14 Nm

C1340020

Firmly press the brake caliper against the brake

•

disc in order to force back the brake pads and
pistons

L

Note:

If the brake pads/pistons cannot be forced back in
this way, there may be some defect in the brake sys­tem!

Connect the brake bleeding device to the bleed

•

screw on the brake caliper
Extract brake fluid from the rear brake circuit

•

00.51

When installing:

Installation is the reverse of the removal proce-

•

dure
– Add brake fluid up to the top of the sight glass
– Bleed the rear brake circuit

Check the function of the brake system

•

Bleeding rear brake circuit

e

Attention:

On vehicles with
described in the repair manual must be supplement­ed by bleeding operations using the

MoDiTeC/DIS plus with the ABS control unit

BMW

toolbox.
Failure to use the
in a hazard of residual air remaining in the ABS con­trol circuits.

– Add brake fluid until it reaches the top of the

sight glass

Connect the brake bleeding device to the bleed

•

screw on the brake caliper

Bleed vehicle with

[ABS]

•

•

MoDiTeC/DIS plus

BMW

Open the bleed screw by half a turn

the brake service operations

ABS

MoDiTeC/DIS plus results

BMW

Variator drive belt replacement

(Inspections II and III)

1

C1000240

Remove fasteners (1)

•

Remove vent cover

•

e

Attention:

Brake fluid level must not drop below the MIN mark
during the bleeding process, otherwise air will be
drawn into the brake system. Bleed the system
again if this happens!

Extract brake fluid until it emerges clear and free

•

of air bubbles

Tighten the bleed screw

•

Check the operation of the brake system

•

Operating fluid:

Brake fluid .....................................................DOT 4

X

Torque specification:

Bleed screw ................................................. 14 Nm

2

C1000250

Remove fasteners (2)

•

Remove variator cover

•

When installing:

Note positions of vent hose and bracket (arrow)

•

00.52

Check belt

Check for cracks

•

Check width of belt

•

Wear data:

Belt width ....................................17.8 mm/0.701 in

When installing:

The legend on the belt must be visible from the out­side

11 7 521

C1000261

Use retainer,

•

terpressure and remove the attachment from the
driven variator
Press variator plates together and turn them an-

•

ticlockwise
Remove belt together with driven variator

•

Clean housing and variator cover

•

BMW No. 11 7 521,

to apply coun-

C1000270

Make sure the belt is correctly seated

•

Install belt together with driven variator

•

Check by turning variator manually to ensure that

•

belt is not trapped

X

Torque specification:

Driven variator mount ................................... 60 Nm

00.53

Checking clutch lining

Clean variator filter screen

(Inspection III)

H

h

C1110540

Remove bell housing; use puller if necessary

•

Check clutch plate lining replace if necessary

•

L

Note:

Replacing driven variator without clutch (a24.6).

a

................................................... See Group 21

(Inspections II and III)

Remove fasteners (1)

•

Remove vent cover

•

1

C1000240

Wear data:

Pad, wide H............................... 4.0 mm/0.15748 in

Pad, narrow h............................2.5 mm/0.09842 in

Remove filter screen from retaining lugs and

•

clean
Clean inside of vent cap

•

C1000280

00.54

Drive variator

Remove drive variator

L

Note:

The following description of variator removal applies
to both the lubricated and the unlubricated versions!
Note differences during assembly!

11 7 521

Check, clean and grease drive variator (lubricated version)

(Inspection II, III) (lubricated version)

C1000440

C1000291

L

Note:

The nut is secured with thread-locking compound!

Undo nut (arrow) using retainer

•

BMW No. 11 7 521

Remove outer washer and drive variator with

•

spacer
Clean locking compound from threads on crank-

•

shaft

When installing:

While installation is basically a reversal of the re-

•

moval process, careful attention should be di­rected toward the following operations:
Observe assembly instructions for lubricated

•

(a00.56) and unlubricated variators (a00.58)

1

2

3

4

6

5

7

C1110491

Undo attachment bolts (5) and remove cover (4)

•

Remove driver (3) and sliders (2) with spring clips

•

Remove rollers (1)

•

Clean all parts with shop towels

•

Check shaft sealing rings for damage and cor-

•

rect seating
Check O-ring (7) for damage and flat spots

•

L

Note:

The bearing tube (7) (spacer) is equipped with a
continuous lubrication passage (arrow)! Install only
bearing tube with lubrication passage on lubricated
versions of the drive variator!

00.55

C1000480

When installing:

While installation is basically a reversal of the re-

•

moval process, careful attention should be di­rected toward the following operations:

L

Note:

The rollers in the frame may display flat spots within
the wear limits!
Wear within the specified wear limits is acceptable!
Visible, palpable roller wear (arrows) on the drive
plate's tracking surfaces is acceptable!

Conduct visual inspection

•

Replace drive variator as required

•

C1111300

Evenly apply approximately 20 g (0.7 oz) of

•

grease to the contact path of the inner plate
Lightly grease O-ring and install

•

Place spring, sliders on transfer elementand

•

grease recesses in sliders

L

Note:

The bearing tube (spacer) is equipped with a contin­uous lubrication passage! Install only bearing tube
with lubrication passage on lubricated version of
drive variator!

Apply even coat of grease to inside of bearing

•

tube (spacer)
Spray ground faces of crankshaft stub

•

Place transfer element in position

•

Check action of transfer element

•

Secure variator cover

•

Fluids and lubricants:

Shell Retinax HDX2 .......approximately 20 g (0.7 oz)

Spacer and contact

surface ..............................Klüber paste 46 MR 401

Crankshaft stub.................Klüber paste 46 MR 401

00.56

X

Torque specification:

Variator cover attachment .............................. 4 Nm

Drive variator attachment

(+ LOCTITE 243) .......................................... 60 Nm

Variator cover............................................... 10 Nm

Vent cover...................................................... 9 Nm

Check and clean drive variator (unlu­bricated version)

(Inspection II, III) (unlubricated version)

C1000450

1

2

C1000470

L

Note:

Flat spots on the rollers that do not not exceed the
wear limits are acceptable!
Wear within the specified limits is acceptable!
Visible and palpable contact tracks (arrows) caused
by motion of rollers through their travel paths are ac­ceptable!

3

5

Remove transfer element (3), then extract

•

sliders (5) with spring (4)
Remove rollers (1)

•

Clean all parts with shop towels

•

L

Note:

The bearing tube (2) (spacer) does not have a lubri­cation passage!

4

C1000460

Conduct visual inspection

•

Replace drive variator as necessary

•

00.57

When installing:

While installation is basically a reversal of the re-

•

moval process, careful attention should be di-

rected toward the following operations:

C1000490

Do not lubricate drive variator during assembly or

•

installation -

Check action of transfer element

•

do not

grease

Replacing complete drive variator

(Inspection II) every 22,500 km (13,500 miles) –
lubricated version only

11 7 521

C1000291

L

Note:

The nut is secured with thread-locking compound!

X

Torque specification:

Drive variator mount

(+ LOCTITE 243)........................................... 60 Nm

Variator cover............................................... 10 Nm

Vent cover...................................................... 9 Nm

Use retainer

•

plate, then remove drive variator with spacer
Clean locking compound from crankshaft

•

threads

Clean housing and variator cover

•

BMW No. 11 7 521

to undo outside

C1000300

00.58

When installing:

Observe installation instructions for lubricated

•

(a00.56) and unlubricated variator (a00.58)
Spray shaft as necessary

•

Fluids and lubricants:

Shaft ................................ Klüber paste 46 MR 401

Mount for drive variator .................... LOCTITE 243

e

Attention:

Make sure that belt is not trapped between the belt
plates!

X

Torque specification:

Mount, drive variator

(+ LOCTITE 243)........................................... 60 Nm

Variator cover............................................... 10 Nm

Vent cover...................................................... 9 Nm

Checking wheel bearing float

(Inspection III)

L

Note:

Check bearing float with cold bearing only.

Take the weight off the front/rear wheel

•

Tilt the front/rear wheel back and forth on the

•

axle
It should not be possible to feel any lost motion

•

If play is detected in the wheel bearings, replace

•

them

a

................................................... See Group 36

00.59

Check to ensure that leading link bearing has zero play

Check battery electrolyte level - add distilled water if necessary

(Inspection I, IV)

Checking steering bearing play

Relieve load on front wheel

•

C1000310

Move fixed fork tubes forward (arrows)

•

If play is detected, check fastener of leading-link

•

mount and adjust if necessary

a

................................................... See Group 31

(Inspection IV)

d

Warning:

Battery acid is extremely caustic.
Protect your eyes, face, hands, clothing and the
paintwork!

e

Attention:

Observe precautions for working with battery acid!

Checking battery electrolyte level

– Open cover of rear storage compartment

max

min

Remove cover from battery compartment

•

The electrolyte level must be between:

•

Maximum level
Minimum level

"UPPER LEVEL"

"LOWER LEVEL"

C1000320

and

00.60

Adding distilled water

max

min

Checking Bowden cables

(Inspections III and IV)

Check Bowden cables for damage from rubbing

•

and abrasion
Check freedom of movement and adjust, if nec-

•

essary

a

................................................... See Group 32

Throttle cable:

Move the handlebars all the way from left to right

•

and ensure that throttle valve does not move

C1610030

Remove threaded plug

•

L

Note:

Never use anything other than distilled water to top
up the battery's electrolyte!

Add distilled water up to the maximum level

•

Installation is the reverse of the removal proce-

•

dure

Clean/grease battery terminals if necessary

(Inspection IV)

– Remove cover from battery compartment

Clean the battery terminals and grease them with

•

acid-proof battery grease

Fluids and lubricants:

Battery terminal ..........Acid-resistant battery grease

Checking easy-lift mechanism

(Inspections I, II, III and IV)

Check operation of mechanism and check free-

•

dom of movement
Check Bowden cables for damage from rubbing

•

and abrasion
Check free travel of Bowden cables and adjust

•

as required

Specification:

– The small lever must move up and down be-

tween the two limit stops

– Adjust Bowden cables without free travel, allow-

ing the stand springs to hold the stand in its end

a

position (

46.44)

00.61

Checking windscreen washer

Checking safety elements

(Inspections I, II and III)

45°

15°

Check spray pattern of nozzles; adjust if neces-

•

sary

Use a screwdriver to adjust nozzles

•

Top up windscreen-washer fluid

•

45°

C1610250

Check windscreen wiper

(Inspections II, III and IV)

Check wiper blade for cracks

•

Check action of wiper arms

•

Check windscreen wipers and replace wiper

•

blade if necessary

a

................................................... See Group 61

(Inspections I, II, III and IV)

Check Bowden cable for central seat­belt release

72 5 501

C1720050

Use test gauge,

•

sion release lever
Engage seat belts in their buckles with an audi-

•

ble click
Move the handlebars all the way from left to right

•

and ensure that belt buckles do not disengage
If necessary, check Bowden cable for central

•

seat-belt release

BMW No. 72 5 501

, to preten-

Check belt straps and belt buckles

Fully unreel seat belts and check for damage

•

Check inertia reels

Once unreeled, belt must reel in automatically

•

when released

Check inertia-reel's detent mechanism to ensure that it engages correctly

Engage seat belts in their buckles with an audi-

•

ble click
Pull firmly on belt strap and make sure that inertia

•

reel locks

00.62

Examine crash elements

Replacing fuel filter

(Inspections I, II, III and IV)

Examine foam-rubber element from below for

•

damage and cracks; replace if necessary

a

................................................... See Group 46

Check shoulder bar and deforma­tion element

(Inspections I, II, III and IV)

Check deformation element for damage; replace

•

if necessary
Check shoulder bars for damage; replace if nec-

•

essary

a

................................................... See Group 46

Measure shoulder bar

(Inspection II) every 37,500 km (22,500 miles )

– Remove left service cover

17 5 500

13 3 010

Use clamp,

•

fuel lines
Open hose clamp with pliers,

•

Replace fuel filter

•

Installation is the reverse of the removal proce-

•

dure
Note specified flow direction when installing

•

BMW No. 13 3 010,

1

13 3 010

C1160090

to seal off the

BMW No. 17 5 500

x

C1460950

Measure gap (x) between shoulder bars

•

Record result

•

Measurement levels

1 Runout of lower radius (arrows)

Wear data:

Gap "x"..............................................612…616 mm

............................................ (24.0945…24.2520 in)

00.63

Replacing boot in brake-control
assembly (master cylinder), only
with optional ABS

(Inspection III) every 30,000 km (18,000 miles )

For greater clarity the illustrations show the brake­control assembly removed

– Drain the brake system

a

...........................................Assembly Group 34

– Remove handlebar lever

a

...........................................Assembly Group 32

When installing:

While installation is basically a reversal of the re-

•

moval process, careful attention should be di­rected toward the following:

e

Attention:

Observe correct sequence for individual parts!

1

3 5

2

4 6

9

C1320160

e

Attention:

Do not allow brake fluid to come into contact with
painted parts of the motorcycle - brake fluid attacks
paint. Use a lint-free cloth to close off the open ori­fice and prevent any residual brake fluid from leaking
out!

L

Note:

If no circlip is present, the entire unit must be re­placed.

Remove circlip (arrow)

•

Remove piston

•

Remove boot

•

10

1Stud
2 Rubber boot
3 Outer support ring
4Pistons
5Seal
6Spring
7Insert
8O-ring
9 Inner support ring
10 Lock ring

Install new repair kit

•

e

Attention:

When bleeding a brake system that was previously
drained, pull the hand brake lever repeatedly during
the bleeding operation to counter the - danger that
residual air will remain in the brake system!

– Fill/bleed brake system

Front brake (
Rear brake (a34.36)

8 7

a

34.35)

C1320170

00.64

Check mounts

(Inspection I)

Final inspection with road safety and operation check

Check that bolts and nuts are securely tightened:
–Engine mounts
– Rear wheel
– Front wheel

e

Attention:

Never re-use the original nut on the rear wheel!

X

Torque specifications:

Floating axle, front........................................ 30 Nm

Floating axle joint ......................................... 21 Nm

Tube link support bearing............................. 73 Nm

Engine mounts ............................................. 73 Nm

Rear lug nut

(use one time only) ..................................... 130 Nm

(Inspections II, III and IV)

e

Attention:

Remove the vehicle stand,

Check wheels and tyres

•

Check tyre pressures and correct if necessary

•

Tyre tread depth (recommended minimum)

d

Warning:

Comply with legal requirements for minimum tread
depth!

Front wheel .................................... 2 mm/0.0787 in

Rear wheel ..................................... 3 mm/0.1181 in

Tyre pressures (tyres cold)

Solo

Front wheel ................................. 1.9 bar/27.58 psi

Rear wheel ................................. 2.1 bar/30.48 psi

With full load

Front wheel ................................. 1.9 bar/27.58 psi

Rear wheel ..................................2.4 bar/34.83 psi

BMW No. 00 1 570

.

Roadworthiness check

Clutch

•

Steering

•

Brakes, front and rear

•

Condition of tyres and rims, tyre pressures

•

Lights and signalling equipment, indicator and

•

warning lights, instruments
Trial run if necessary

•

00.65

00.66

11

11 Engine

Contents

Technical Data

C1 engine

C1 lubrication

C1 drivetrain

# Operations performed with powertrain cradle installed

Swivel out powertrain cradle

Lock engine at TDC

# Checking valve clearances

# Adjusting valve clearances

Removing and installing powertrain cradle

Replacing grooved ball bearing for engine mount

................................................................................................................................3

.......................................................................................................................................... 9

............................................................................................................................... 10

.................................................................................................................................. 11

............................................................................................... 12

................................................................................................................... 14

............................................................................................... 15

............................................................................................... 16

.................................................................17

......................................................... 19

Page

................................... 12

# Replacing ignition cover

Replacing oil pump

Removing and installing oil pump ...................................................................................................... 20

Measuring oil pump ...........................................................................................................................21

......................................................................................................................20

Water pump removal, installation, replacement

Removing water pump ....................................................................................................................... 21

Replacing shaft oil seals ....................................................................................................................22

Install water pump ............................................................................................................................. 23

# Replacing oil pressure switch

# Replacing oil filter

.....................................................................................................................24

# Replacing pressure-relief (bypass) valve

# Replacing filter screen

Replacing oil seal on crankshaft

Removing crankshaft oil seal .............................................................................................................25

Installing crankshaft oil seal ...............................................................................................................25

Cylinder head

................................................................................................................................26

........................................................................................................ 19

.............................................................. 21

.............................................................................................24

........................................................................24

............................................................................................................25

............................................................................................25

# Dual temperature sensor removal, installation, replacement

Bucket tappet removal, installation, replacement

.......................................................... 26

................................26

11.1

Contents

Page

Inlet and exhaust valve

Removing valves ...............................................................................................................................27

Check valve guide for wear ............................................................................................................... 29

Check valve seat for wear .................................................................................................................. 30

Regrinding valve seats ......................................................................................................................30

Check valve for wear .........................................................................................................................31

Check valve springs for wear .............................................................................................................31

Install valves ...................................................................................................................................... 32

# Check timing chain

# Replacing chain tensioner

# Cylinder head cover removal and installation

Camshaft, camshaft sprocket, camshaft bearing cap

Removing and installing camshaft sprockets .....................................................................................35

Camshaft bearing cap/camshaft removal, installation, replacement ...................................................36

Checking camshafts ..........................................................................................................................38

Replacing chain rails

Chain rail replacement ....................................................................................................................... 38

Replacing guide rail ...........................................................................................................................39

Replacing chain tensioner rail ............................................................................................................39

Timing chain removal, installation, replacement ................................................................................. 40

...............................................................................................................27

................................................................................................................33

....................................................................................................33

............................................................... 34

................................................. 35

................................................................................................................38

Cylinder head removal and installation

Cylinder liner removal ........................................................................................................................41

Checking cylinder dimensions ...........................................................................................................41

Replacing stud bolts .........................................................................................................................42

Piston removal, installation, replacement

Replacing piston rings .......................................................................................................................43

Checking piston dimensions ............................................................................................................. 44

Measuring piston pin .........................................................................................................................44

Removing crankshaft

Measuring end float ...........................................................................................................................45

Measuring housing

Measuring main bearings

Replacing bearing shells

Removing bearing shells ................................................................................................................... 46

Installing bearing shells .....................................................................................................................47

Replacing cylindrical pin for starter double gear ................................................................................48

Installing crankshaft ........................................................................................................................... 48

Measuring end float in housing .......................................................................................................... 48

Joining halves of crankcase

...............................................................................................................45

....................................................................................................................46

..........................................................................................................46

...........................................................................................................46

.....................................................................................................49

................................................................................40

...........................................................................42

11.2

11

Technical Data C1 C1 200

Engine, general

Single-cylinder four-stroke, double overhead
camshafts driven by roller chain, 4 valves operat­ed by bucket tappets, liquid-cooled cylinder and
cylinder head, integral water pump, automatic
transmission.

Layout 1 cylinder, four-stroke

Engine number Variator housing output shaft

Number of cylinders 1

Stroke mm (in) 50 (1.96850) 58.4 (2.29921)

Cylinder bore mm (in) 56.4 (2.22047) 62.0 (2.44094)

3

Displacement cm

125 (10.125) 176 (14.256)

(cu. in.)

Compression ratio :1 13.0 ± 0.3 11.5 ± 0.3

Power rating kW (bhp) 11 (15)

at 9,250 rpm

Max. torque Nm 12

at 6,500 rpm

13 (18)
at 9,000 rpm

17
at 6,500 rpm

Idle speed rpm 1,900

Max. power at rpm 9,250 9,000

Max. engine speed rpm 10,400

Crankshaft (main) bearings Plain bearing

Direction of rotation Clockwise, looking at ignition system

Cylinders Light alloy, Nikasil liners

Pistons Smooth-skirt piston

Lubrication system

Engine lubrication Pressurised oil circuit

Oil filter Full-flow type

Oil pump Eaton pump

Oil capacity

Initial filling l (Imp pint/

1 (1.76/1.05)

US quart)

Oil change with filter l (Imp pint/

1 (1.76/1.05)

US quart)

Min. capacity l (Imp pint/

0.8 (1.41/0.85)

US quart)

Oil grades 15W-40

Winter operation 5W-40

Oil pressure:

(idle) bar (psi) ≥ 0.5 (7.11) (oil temperature 80 °C/176 °F)

7,500 rpm bar (psi) 3 (43.54)

Max. allowed oil consumption l/100 km

0.01 (1.76/1.05)

(miles per Imp

pint/miles per

US quart)

BMW recommends Castrol

11.3

Technical Data C1 C1 200

Crank assembly with conrod

Main bearing bore diameter

Installed dimension mm (in)

Wear limit mm (in) 32.07 (1.2626)

Crankshaft - main bearing play

Installed dimension mm (in) 0.030…0.070 (0.001…0.002)

Wear limit mm (in) 0.10 (0.0039)

Main bearing diameter mm (in) 32.015…32.025 (1.2604…1.2608)

Wear limit mm (in) 32.01 (1.2602)

Runout mm (in) 0.07 (0.0028)

Runout at crankshaft journal

Clutch end mm (in) 0.05 (0.0020)

Reluctor end mm (in) 0.05 (0.0020)

Runout connecting rod

Big-end bore mm (in) 0.016…0.060 (0.0006…0.0024)

Wear limit mm (in) 0.07 (0.0028)

Small-end bore mm (in) 0.03 (0.0012)

Connecting rod axial float between
crank webs

Axial float at connecting rod bearing

Installed dimension mm (in) 0.25…0.33 (0.009…0.012)

Wear limit mm (in) 0.80 (0.0315)

Runout at connecting rod bearing

Installed dimension mm (in) 0.016…0.060 (0.0006…0.0024)

Wear limit mm (in) 0.07 (0.0028)

Inside Ø of wristpin end bush

Installed dimension mm (in) 15.003…15.008 (0.5907…0.5909)

Wear limit mm (in) 15.03 (0.5917)

Crankshaft axial float mm (in) 0.2…0.4 (0.007…0.015)

Cylinder head

Max. surface irregularity mm (in) 0.05 (0.0019)

Camshaft journals I/E mm (in) 17.969…17.980 (0.7079…0.7078)

Wear limit mm (in) 17.96 (0.707)

Camshaft

Camshaft bearing bridge I/E mm (in) 18.02…18.04 (0.709…0.710)

mm (in) 0.8 (0.0315)

Wear limit mm (in) 18.07 (0.711)

Bearing width mm (in) 23.8…23.9 (0.93…0.94)

Wear limit mm (in) 23.7 (0.93)

11.4

Technical Data C1 C1 200

Camshaft

Inlet ° 276

Exhaust ° 264

Bearing cap

Bearing journal diameter mm (in) 18.01…18.03 (0.709…0.7099)

Wear limit mm (in) 18.05 (0.7106)

Inlet camshaft

Bearing journal diameter mm (in) 17.969…17.980 (0.7074…0.7078)

Wear limit mm (in) 17.96 (0.7070)

Exhaust camshaft mm (in) 17.969…17.980 (0.7074…0.7078)

Bearing journal diameter mm (in) 17.96 (0.7070)

Bucket-type tappet

Bore Ø in cylinder head mm (in) 26.007…26.008 (1.02389…1.02393)

Wear limit mm (in) 26.04 (1.0252)

Extl. dia. mm (in) 25.980…25.993 (1.0228…1.0239)

Wear limit mm (in) 25.97 (1.0224)

Radial play mm (in) 0.10 (0.0039)

Valves

Valve clearances with engine cold (max. 35 °C/95 °F)

Inlet valve mm (in) 0.05…0.14 (0.0019…0.0055)

Exhaust valve mm (in) 0.20…0.29 (0.0079…0.0114)

Valve timing (at 1 mm/0.04 in valve clearance)

Inlet opens 24° before TDC

Inlet closes 36° after BDC

Exhaust opens 34° before BDC

Exhaust closes 14° after TDC

Valve head dia.

Inlet mm (in) 21.2 (0.08346)

Exhaust mm (in) 19 (0.7480)

Stem dia.

Inlet mm (in) 3.957…3.981 (0.1558…0.1567)

Wear limit mm (in) 3.94 (0.1551)

Exhaust mm (in) 5.945…5.960 (0.2340…0.2346)

Wear limit mm (in) 5.935 (0.2336)

Runout mm (in) 0.06 (0.0023)

Valve stem rock - installed clearance

Inlet mm (in) 0.0160…0.058 (0.0006…0.0023)

Wear limit mm (in) 0.130 (0.0051)

Exhaust mm (in) 0.031…0.073 (0.0012…0.0029)

Wear limit mm (in) 0.145 (0.0057)

11.5

Technical Data C1 C1 200

Valve guide

Inlet/exhaust inside diameter mm (in) 4.002…4.015 (0.1576…0.1581)

Wear limit mm (in) max. 0.5 (0.0197)

Projection mm (in) 9.8…10.2 (0.3858…0.4016)

Valve seat angle

Inlet ° 45

Exhaust ° 45

Included angle between valves

Inlet ° 16

Exhaust ° 18

Valve seat width

Inlet mm (in) 1.185…1.215 (0.0466…0.0478)

Wear limit mm (in) 2 (0.0787)

Inspection 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) 2 (0.0787)

Inspection dimension mm (in) 1.2…1.6 (0.0472…0.0630)

2

Valve seat surface mm (in)

Wear limit mm (in)

0.8 (0.0315)

2

0.6 (0.0236)

Bucket tappets (wear limit)

Extl. dia. mm (in) 25.980…25.993 (1.0228…1.0239)

Radial play in cylinder head mm (in) 0.100 (0.0039)

Guide Ø in cylinder head mm (in) 26.007…26.008 (1.02389…1.02393)

Wear limit mm (in) 26.04 (1.0252)

Valve spring

When new (uncompressed) mm (in) 36.93 (1.4539) 41.0 (1.6142)

Wear limit mm (in) 36.7 (1.4449) 40.8 (1.6063)

Oil circuit bypass valve

Compression spring for pressure-re-

mm (in) 13.5 (0.5315)

lief valve, uncompressed

Wear limit mm (in) 13.4 (0.5276)

Pistons

Clearance, piston and cylinder new mm (in) 0.013…0.037 (0.0005…0.0015)

Wear limit mm (in) 0.060 (0.0024)

Piston diameter “A”

Installed dimension mm (in) 56.37 ± 0.005

(2.2193 ± 0.00002)

61.97 ± 0.005
(2.4398 ± 0.00002)

Piston diameter “B”

Installed dimension mm (in) 56.38 ± 0.005

(2.2197 ± 0.00002)

11.6

61.98 ± 0.005
(2.4402 ± 0.00002)

Technical Data C1 C1 200

Piston pin

Extl. dia. 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 (0.0012)

Piston wristpin bore diameter mm (in) 15.003…15.008 (0.5907…0.5909)

Wear limit mm (in) 15.03 (0.5917)

Piston rings

1st groove taper faced compression ring

End gap mm (in) 0.15…0.35

(0.0059…0.0138)

Wear limit mm (in) 0.8 (0.0315) 0.7 (0.0276)

Ring grooves/vertical gap mm (in) 1.02…1.04

(0.0402…0.0409)

Wear limit mm (in) 0.1 (0.0039) 0.1 (0.0039)

Ring height R thickness mm (in) 0.975…0.990

(0.0384…0.0390)

Wear limit mm (in) 0.97 (0.0382) 0.97 (0.0382)

Height of groove mm (in) 1.35 (0.0531) 1.02…1.04

2nd groove taper faced hook scraper ring

Gap clearance mm (in) 0.15…0.35

(0.0059…0.0138)

Wear limit mm (in) 0.8 (0.0315) 0.8 (0.0315)

Ring grooves/end clearance mm (in) 1.22…1.24

(0.0480…0.0488)

Wear limit mm (in) 0.1 (0.0039) 0.1 (0.0039)

Ring height R thickness mm (in) 1.175…1.190

(0.0463…0.0469)

Wear limit mm (in) 1.17 (0.0461) 1.17 (0.0461)

0.20…0.25
(0.0079…0.0098)

0.064…0.03
(0.0025…0.0012)

0.978…0.990
(0.0385…0.0390)

(0.0402…0.0409)

0.20…0.35
(0.0079…0.0138)

0.065…0.03
(0.0026…0.0012)

1.175…1.190
(0.0463…0.0469)

Height of groove mm (in) 1.22…1.24

(0.0480…0.0488)

3rd groove oil scraper ring

Gap clearance mm (in) 0.4…1.4

(0.015…0.055)

Wear limit mm (in) 1.5 (0.0591) 1.0 (0.0394)

Ring grooves/height mm (in) 2.01…2.03

(0.079…0.080)

Wear limit mm (in) 0.5 (0.0197) 0.2 (0.0079)

Ring height (thickness) mm (in) 2 (0.0787) 1.85…2.00

Height of groove mm (in) 2.60 (0.1024) 2.01…2.03

0.2…0.7
(0.0079…0.0276)

0.01…0.1
(0.0004…0.004)

(0.0728…0.078)

(0.0791…0.0799)

11.7

Technical Data C1 C1 200

Direction of installation Arrow on piston crown points toward exhaust

Cylinders

Bore

Cylinder “A” mm (in) 56.388…56.398

(2.2200…2.22204)

Cylinder “B” mm (in) 56.402…56.412

(2.2206…2.2209)

Timing chain

Distance from sealing face to chain tensioner plunger

Wear limit mm (in) 6 (0.2362)

Water pump

Water-pump shaft bearing in housing mm (in) 10.05…10.07 (0.395…0.396)

Wear limit mm (in) 10.08 (0.3968)

Oil pump

Oil-pump gear

Axial run-out mm (in) 0.3 (0.0118)

Oil-pump shaft outside diameter mm (in) 7.972…7.987 (0.3139…0.3145)

Wear limit mm (in) 7.96 (0.3134)

61.988…61.997
(2.4404…2.4408)

62.003…62.012
(2.4411…2.4414)

Wear limit in housing mm (in) 8.03 (0.3161)

11.8

C1 engine

R11C160 engine

11.9

C1 lubrication

11.10

R11C161 lubrication

C1 drivetrain

R24C161 TSS

11.11

# Operations performed with power­train cradle installed

L

Note:

Operations identified by # can also be carried out
with the powertrain cradle installed.

Left side

Spark plug

•

Oil pressure switch

•

–Drive variator, front
– Driven variator, rear
– Gearbox

a

....................................................See Group 24

– Centrifugal coupling

a

....................................................See Group 21

– Starter motor

a

....................................................See Group 12

Temperature sensor

•

Swivel out powertrain cradle

For enhanced clarity some of the illustrations show
the components with the powertrain cradle re­moved.

Secure front wheel

•

Right side

Timing-chain tensioner

•

Chain guide

•

Chain guide rail

•

Camshafts and camshaft bearings

•

Bucket-type tappet

•

– Magneto ignition
– One-way clutch

a

....................................................See Group 12

Oil pump assembly

•

Starter idler gear

•

Water pump drive gear

•

Water pump

•

C1000090

Remove lines from clip (arrow):

•

–Alternator
– Ignition signal sensor

Open the seat

•

C1000100

Open clip and disconnect plug from oxygen sen-

•

sor (arrow)

11.12

C1000110

C1000130

Remove lines from clips:

•

–Injector
– Air temperature sensor
– Idle actuator
– Coolant temperature sensor to cylinder head

C1000120

Release coolant hose from clip at injector and

•

bracket (arrow) on variator cover

Remove hose from bracket at intake-air plenum

•

chamber (arrow)

33 1 531

00 1 580

00 1 570

C1000140

Position vehicle hoist,

•

attachment
point
Slightly raise vehicle with lifter

•

Install fitting,

•

spring strut and powertrain cradle
Remove lower end of spring strut at brake caliper

•

bracket

BMW No. 00 1 580,

BMW No. 33 1 531,

BMW No. 00 1 570,

at separation

between left

with

e

Attention:

To avoid overstretching hoses and wiring do not
swivel powertrain cradle more than max. 20°!

Lift C1 no further than travel stop: powertrain

•

cradle swivels down

11.13

When installing:

Install the cylinder head cover before installing

•

the powertrain cradle

e

Attention:

Make sure that gasket and cover are free of oil!

Installing cylinder head cover

•

e

Attention:

When lowering watch the struts and the duct to the
air plenum chamber!

L

Note:

Make sure the detent for the long lever of the easy­lift mechanism engages! If necessary, move the le­ver to the drive position first, and then move it to the
park position!

X

Tightening torque:

Cylinder head cover ..................................... 10 Nm

Strut, bottom ................................................ 21 Nm

C1000200

L

Note:

Watch for dirt and contamination adjacent to the
starter/threaded plug (arrow) - do not allow contam­inants to enter the engine!

Lock engine at TDC

C1130010

Loosen hose clamp (arrow) on intake-air plenum

•

chamber

11 7 651

C1000220

Undo the Allen bolt adjacent to the starter and

•

use set bolt,
gine at TDC

BMW No. 11 7 651,

to lock the en-

11.14

11 34 004

– Remove left and right service covers

a

....................................................See Group 46

– Swivel out powertrain cradle (
– Remove cylinder head cover (a11.34)
– Remove spark plug (a12.5)

Turn over engine at camshafts, continuing until

•

the lobes are pointed outward

Measure valve clearance using single feeler

•

gauge blade
Record the valve clearances

•

and adjust valve clearance as necessary (replace

•

tappets) (a11.16)

# Checking valve clearances

a

11.12)

C1111001C1000170

When installing:

Install the cylinder head cover before installing

•

the powertrain cradle

e

Attention:

Make sure that gasket and cover are free of oil!

Installing cylinder head cover

•

e

Attention:

When lowering watch the struts and the duct to the
intake-air plenum chamber!

L

Note:

Make sure that detent for long lever of the easy-lift
mechanism engages! If necessary, move the lever to
the drive position first, and then move it to the park
position!

Swiveling powertrain cradle back

•

X

Tightening torque:

Cylinder head cover ..................................... 10 Nm

Strut, lower .................................................. 21 Nm

Adjustment data:

IV left
mm (in)

0.05
Spec.
clearance

Clearance,
measured
(used)

Difference

Inlet valve clearance........................0.05…0.14 mm

................................................ (0.0019…0.0055 in)

Exhaust valve clearance ..................0.20…0.29 mm

.................................................. (0.0079 0.0114 in)

0.14

(0.0019

0.0055)

0.15

(0.0059)

0.01

(0.00039)

IV right
mm (in)

0.05

0.14

(0.0019

0.0055)

EV left
mm (in)

0.20

0.29

(0.0079

0.0114)

0.15

(0.0059)

-0.05

(-0.00197)

EV right
mm (in)

0.20

0.29

(0.0079

0.0114)

11.15

11 34 004

– Swivel out powertrain cradle (a11.12)
– Checking valve clearances (a11.15)
– Removing camshaft bearing caps/camshafts

a

(
Remove tappets

•

Record the figures on the bottoms of the tappets

•

Sample calculation:

# Adjusting valve clearances

11.36)

IV left
mm (in)

IV right
mm (in)

EV left
mm (in)

EV right
mm (in)

L

Note:

The bucket tappets are available in sizes ranging
from 2.50 mm (0.09842 in) to 3.20 mm (0.12598) in
in 5/100ths graduations.
Should it prove impossible to adjust the valve clear­ance with the smallest bucket tappet (2.50 mm/

0.09842 in) the cylinder head will have to be re-

a

placed (
Should it prove impossible to adjust the valve clear­ance with the largest bucket tappet (3.20 mm/

0.12598 in), it will be necessary to regrind the valve
seat (a11.30).

11.40).

Spec.
clearance

Clearance,
measured
(used)

Difference

Bucket,
measured
(used)

Bucket
specifica­tion (new)

Bucket,
measured
(new)

Specified
clearance
(new)

Clearance,
measured
(new)

0.05

0.14
(0.0019

0.0055)

0.15
(0.0059)

0.01
(0.00039)

2.80

(0.1102)

2.81
(0.1106)

2.85
(0.1122)

0.10
(0.0039)

0.05

0.14
(0.0019

0.0055)

0.20

0.29
(0.0079

0.0114)

0.15
(0.0059)

-0.05
(-0.0019)

2.80

(0.1102)

2.75
(0.1083)

2.75
(0.1083)

0.20
(0.0079)

0.20

0.29
(0.0079

0.0114)

When installing:

While installation is basically the reversal of the

•

removal procedure, special attention should be
devoted to the following points:

Observe installation instructions for camshaft

•

bearing caps/camshafts (a11.37)

e

Attention:

Remove TDC set bolt,

Turn the engine over several times by hand

•

Recheck valve clearances

•

BMW No. 11 7 651!

Subtract negative difference of bucket (old)

•

Add positive difference of bucket (old)

•

Note sizes of available bucket tappets

•

11.16

11 00 060

Removing and installing

powertrain cradle

– Remove left service cover
– Remove the right rear side section

C1000080

Disconnect cables and lines:

•

– Air temperature to intake air silencer
–Oxygen sensor
– Ignition signal sensor
–Alternator
– Idle actuator
– Water temperature
– Starter - and + cables
– Oil pressure switch

L

Note:

Pull both cables through toward the right and disen­gage the clip on the water hose.

Disconnect spark plug cap

•

Remove screws securing injector valve

•

Disengage throttle cable from cam disc

•

17 5 500

C1110140

Open hose clamps at return hose and in front of

•

distributor

– Remove silencer (muffler)

a

.................................................... See Group 18

– Remove secondary swing arm

a

.................................................... See Group 33

Remove lug nut

•

Position floor jack on powertrain cradle beneath

•

gearbox and raise the jack until the rear wheel is
clear of the ground
Detach bottom of strut and tie it up out of the way

•

L

Note:

Swing the brake anchor forward and pull the bush­ing out of the wheel. Pull brake anchor with brake
caliper carefully away from the brake disc. Remove
brake anchor with brake caliper.

– Remove rear wheel

a

.................................................... See Group 36

Use hose to drain coolant from drain plug

•

C1110130

11.17

11 0 651

C1110150

Support the weight of the vehicle on floor jack

•

positioned beneath frame
Secure assembly brace,

•

powertrain cradle

BMW No. 11 0 651,

00 1 490

11 0 652

C1110071

When installing:

While installation is the reversal of the removal

•

procedure, special attention should be devoted
to the following points:

1Adding coolant
2 Slacken vent plug in cylinder head until liquid

emerges, then retighten vent plug
3 Pour in remainder of coolant
4 Briefly let engine run, then correct coolant level in

expansion tank

d

Warning:

Never re-use the original 6-point lug nut on the rear
wheel

Fluids and lubricants:

to

Loctite 243
Shell Retinax EP2

X

Torque specification:

Powertrain cradle mount to separation

point............................................................. 73 Nm

Injector mount

(+Loctite 243) ................................................. 4 Nm

Drain plug .................................................... 10 Nm

Vent screw .................................................... 9 Nm

Throttle cable attachment .............................. 8 Nm

Auxiliary swing arm mount............................ 21 Nm

Auxiliary swing arm mount M10

(+ Loctite 243) .............................................. 60 Nm

6-point nut for input shaft........................... 130 Nm

Lower strut mount ........................................ 21 Nm

Silencer mount on auxiliary swing arm ......... 21 Nm

Attachment, exhaust pipe to cylinder head .. 21 Nm

Remove fastener securing suspension and re-

•

move axle
Detach the spring struts from the powertrain cra-

•

dle and tie up out of the way
Using extension,

•

BMW No. 00 1 490

rear to remove

BMW No. 11 0 652

, pull powertrain cradle to the

, and stand,

11.18

Replacing grooved ball bearing for engine mount

– Housing halves separated

Using a pipe D=24.5 mm (0.9646 in) or a 19 mm

•

(0.7480 in) socket and working from the inside,
press out the bearing

C1110160

Using a mandrel D=34 mm (1.3386 in) or a

•

27 mm (1.0630 in) socket and working from the
outside, press in the bearing

11 11 015

– Remove the right rear side panel

Drain engine oil

•

Remove fastener securing silencer to auxiliary

•

swing arm
Slacken fasteners securing exhaust to cylinder

•

head
Swing silencer to the outside and secure in this

•

position
Disconnect cables under rear side section from

•

ignition sensor and generator
Remove 9 securing screws and lift off cover

•

Remove stator

•

When installing:

Always install a new seal

•

Use 3-Bond 1209 to seal the grommets in cable

•

passage

Fluids and lubricants:

Rubber grommet ............................... 3-Bond 1209

X

Cover to housing

to Engine No.: 745 594 (8.8) ........................ 10 Nm

starting with Engine No.: 745 595 (10.9) ...... 12 Nm

# Replacing ignition cover

Torque specification:

C1110170

11.19

Replacing oil pump

When installing:

11 11 300 Removing and installing oil pump

a

– Remove reluctor (

Turn over the engine until the attachment bolts

•

(arrows) come into view
Release bolts and remove pump

•

12.8)

C1110280

The outer rotor bears a punch mark for identifica-

•

tion

C1110290

L

Note:

Make sure that punch mark is toward inside of pump
housing!

Liberally coat oil-pump channels and preassem-

•

bled pump with oil before installing

Note position of gearwheel (arrow)

•

Coat threads of self-tapping screws with Loctite

•

prior to installation (Tapite screws)

Turn pump so that tooth-edge gap can be

•

checked

Check axial float of pump

•

Fluids and lubricants:

Tapite bolts ........................................... Loctite 243

X

Torque specification:

Oil pump ........................................................ 6 Nm

11.20

Measuring oil pump

C1110300

Check tooth edges of oil pump gear for deforma-

•

tion
Measure protrusions of needle roller

•

Check runout of oil pump gear relative to shaft

•

Check oil pump shaft for wear

•

Wear data:

Runout ..............................max. 0.3 mm (0.0118 in)

Oil pump shaft..................min. 7.96 mm (0.3133 in)

Housing diameter .................... 8.03 mm (0.3161 in)

Remove circlip and washer (arrow)

•

Press water pump gear out of fitting in needle

•

roller

C1110280

Water pump removal, installation, replacement

Removing water pump

–Drain coolant

Slip a length of hose (fuel line or similar) over

•

screw and tool and release the fastener
Undo radiator plug and remove attachment

•

– Remove reluctor

Remove needle roller and washer

•

Remove screw

•

C1110310

11.21

L

Note:

Working from left side of engine, slide a plastic rod
into the water pipe and use it to remove the pump
shaft.

e

Attention:

Do not use a metal rod, as it would damage the wa­ter pump gear!

Remove pump housing

•

e

Attention:

A damaged water-pump shaft can lead to leakage if
installed again!

Remove O-rings

•

Check contact zones of the two sealing rings on

•

the water pump shaft for tracking, damage and
wear

Wear data:

Housing internal Ø ................ 10.08 mm (0.3969 in)

Check water pump impeller for damage and de-

•

formation

Replacing shaft oil seals

11 7 611

C1110321

Use a screwdriver to remove oil seals from hous-

•

ing

When installing:

L

Note:

Before installing, coat outside of shaft oil seals with
petroleum spirit; do not oil!

Coat shaft seal extruded edges with

•

MOLYKOTE 111

e

Attention:

Install shaft seals with flat surfaces facing each oth­er!

Use drift punch,

•

install first shaft seal

Install shim (arrow)

•

Install second shaft seal without shim

•

L

Note:

Make sure that the water drain passage is not ob­structed!

BMW No. 11 7 611,

and shim to

11.22

Install water pump

Prior to installation coat the inner extruded edge

•

seals with MOLYKOTE 111
Fill cavity with MOLYKOTE 111

•

Install water pump with O-rings oiled

•

Liberally oil water pump shaft prior to installation

•

Coat threads of self-tapping screws with Loctite

•

prior to installation (Tapite screws)
Turn water pump shaft by hand and make sure it

•

rotates smoothly with no stiction or excess re­sistance

1

2

Press water pump gear onto needle roller

•

L

Note:

Water pump gear must engage with an audible click
and must mesh with teeth of oil pump gear!

Install thrust washer

•

e

Attention:

Install a new circlip!

Fluids and lubricants:

Tapite bolts ........................................... Loctite 243

Water pump .................................. MOLYKOTE 111

X

Torque specification:

Water pump housing ...................................... 6 Nm

C1110330

Install thrust washer (1)

•

Slide needle roller (2) into shaft, ensure that pro-

•

jection is even

11.23

12 61 000

switch

# Replacing oil pressure

11 11 296

# Replacing pressure-relief

(bypass) valve

When installing:

Remove all traces of old thread-locking com-

•

pound from the threads
Always install a new seal

•

Fluids and lubricants:

Oil-pressure switch ............................... Loctite 243

X

Torque specification:

Oil pressure switch....................................... 12 Nm

11 41 220

# Replacing oil filter

– Drain the oil

1

2

3

C1110351

Unscrew drain plug

•

Remove valve housing (3), spring (2), ball (1)

•

Check joint surface (arrow) for signs of contami-

•

nation

Check ball for damage

•

Clean valve housing

•

Check extended length of spring

•

Wear data:

Spring length........................... 13.4 mm (0.5276 in)

C1000030

Place drain plate,

•

haust pipe
Remove securing screws

•

Remove oil filter cover with O-ring

•

Remove oil filter

•

When installing:

Installation is the reverse of the removal proce-

•

dure
Use new O-ring

•

X

Torque specification:

Threaded plug.............................................. 10 Nm

BMW No. 11 7 661,

on ex-

When installing:

Installation is the reverse of the removal proce-

•

dure

Install with new seal

•

X

Torque specification:

Threaded plug.............................................. 30 Nm

11.24