User manual BMW C1 200 REPAIR MANUAL

[. . . ] 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. 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. [. . . ] 11 7 571 Check gearbox oil level and top up as necessary Fluids and lubricants: Shaft seats . . . . . . . . . . . . . . . . . . . . . . . . Klüber paste 46 MR 401 Shaft oil seal seats . . . . . . . . . . . . Klüber paste 46 MR 401 Gearbox lubricant API GL4. . . . . . . . 95 cm3 (5. 80 cu in) 24. 18 C1110680 Dismantling and assembling gearbox, checking individual components 23 00 043 # Operations with powertrain cradle installed Operations identified by # can also be carried out with the powertrain cradle installed. Preparations For the sake of clarity, these illustrations show the vehicle with the powertrain cradle removed. ­ Removing powertrain cradle (a 11. 17) Clean the individual components and check the following parts for wear: · Bearings and seats of shaft oil seals · All gears for wear at tooth edges · Tooth profile of variator and output shafts · Gears for damage 24. 19 11 11 018 ­ ­ # Gearbox cover removal # Gearbox shaft removal Remove complete variator assembly Drain oil from gearbox Note: Additional work necessary if powertrain cradle is to remain installed: - Remove rear wheel (a 36. 9) - Use strut support L ­ Remove gearbox cover C110690 · Open drain plug (arrow) C1110710 · · · · C1110700 Remove thrust washer (arrow) from intermediate shaft Remove seal Tap output shaft lightly with plastic-headed hammer to release it from interference-fit in grooved ball bearing and shaft oil seal Remove intermediate shaft and thrust washer beneath it · · · Remove securing screws Install two M6x70 screws in threaded sockets (arrows) and pull off cover Use screwdriver to pry out shaft oil seal L Note: shaft complete with cover!Remove variator · · · Check joint surface for damage Check condition of cylindrical rollers Check bearings for discolouration 24. 20 When installing: # Replacing housing shaft oil seal on output shaft Note: Additional work necessary if powertrain cradle is to remain installed: - Remove rear wheel (a 36. 9) - Use strut support L ­ ­ ­ C1110720 Remove complete variator assembly (a 24. 6) Remove gearbox cover (a 24. 20) Removing gearbox shafts (a 24. 20) L Note: side of a thrust washer for intermediate Grease one shaft and attach it to side of large gear! · · · · · · Install seal plug with copper seal Oil stub of intermediate shaft and install Position variator shaft in cover Position output shaft in grooved ball bearing Mount second thrust washer on intermediate shaft Install seal C1110730 Fluids and lubricants: shaft oil seal seats. . . . . . . . . . . . Klüber paste 46 MR 401 · Pry out shaft oil sealing ring, using an angled screwdriver with a second screwdriver for leverage, or with screwdriver resting on housing X plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm Torque specification: Drain Filler plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm 24. 21 When installing: e Attention:shaft oil seal does not contact Make sure that 11 7 592 grooved ball bearing - maintain specified gap! 11 7 601 e Attention: new seal and tighten fasteners in Install cover with cross pattern!When installing: · Install shaft oil seal with extruded edge seal on the inside C1110740 · Install shaft oil seal with assembly press, BMW No. 11 7 592 Adjustment specification: Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 1. . . 0. 3 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (0. 0004. . . 0. 0118 in) Fluids and lubricants: Shaft oil seal seats . . . . . . . . . . . . Klüber paste 46 MR 401 Replacing shaft oil seal for variator shaft in gearbox cover (shaft removed) 11 11 276 # Replacing grooved ball bearing for variator shaft in gearbox cover ­ ­ ­ Remove complete variator assembly (a 24. 6) Remove gearbox cover (a 24. 20) Remove shaft oil seal (a 24. 22) 11 7 571 11 7 581 C1110750 · Uniformly chamfer collar at cover C1110760 e Attention: seal seat - remove gratings Deburr shaft oil spray shaft oil seal seats! e Attention: the joint surface use an old gasTo avoid damaging ket and support on blocks! · Insert dry shaft oil seal with drift punch, BMW No. 11 7 581, continuing until it seats on machined housing surface · Press out grooved ball bearing with tube, BMW No. 11 7 571, D=32 mm (1. 2598 in) or 24 mm (0. 9449 in) socket into gearbox from the outside 24. 22 When installing: e Attention: shafts!Grease seats of Lopen side of the grooved ball bearing must face Note: The inward! 11 11 280 # Replacing grooved ball bearing for variator shaft in housing ­ Remove complete variator assembly (a 24. 6) ­ Remove gearbox cover (a 24. 20) ­ Removing gearbox shafts (a 24. 20) 11 7 550 C1110780 31 5 652 C1110770 Note: To avoid damaging the joint surface, lay an old gasket beneath support plate! L · · · Use spacer tube, BMW No. 31 5 652, to support bearing seat on housing and prevent breakage Use drift punch, D=50 mm (1. 9685 in) or 36 mm (1. 4173 in) socket to press grooved ball bearing with lightly oiled outer diameter in until it seats Remove grooved ball bearing with puller, BMW No. 11 7 550 Fluids and lubricants: Shaft seats . . . . . . . . . . . . . . . . . . . . . . . Klüber paste 46 MR 401 24. 23 When installing: e Attention: shafts!Attention: The 11 11 284 # Replacing grooved ball bearing for output shaft in cover ­ Remove complete variator assembly (a 24. 6) ­ Remove gearbox cover (a 24. 20) Note: To avoid damaging the sealing face, lay an old gasket beneath support plate! L 11 7 550 C1110790 C1110801 · Use drift punch, D=40 mm (1. 5748 in) h=170 mm (6. 6929 in) or 30 mm (1. 1811 in) socket to press against the outer race of the lightly oiled grooved ball bearing to install · Remove grooved ball bearing with puller, BMW No. 11 7 550 Fluids and lubricants: Shaft seats . . . . . . . . . . . . . . . . . . . . . . . Klüber paste 46 MR 401 24. 24 When installing: 11 11 288 Replacing grooved ball bearing for output shaft in housing ­ ­ ­ Removing powertrain cradle (a 11. 17) Separate the housing sections (a 11. 45) Remove output shaft oil seal (a 24. 21) e Attention: shafts!Grease seats of eopen side of the bearing must face inward, toAttention: The ward output shaft! 11 7 571 C1110820 31 5 652 C1110810 Note: To avoid damaging the sealing face, use an old gasket and support on blocks! L · · · Use spacer tube, BMW No. 31 5 652, to support bearing seat against housing and prevent breakage Use drift punch, D=40 mm (1. 5748 in) or 30 mm (1. 1811 in) socket, to press the race of the lightly oiled grooved ball bearing to install Use punch D=42 mm (1. 6534 in) or 24 mm (0. 9449 in) socket BMW No. [. . . ] When installing take pains to ensure that all wiring is routed correctly!Position to avoid potential rubbing and abrasion! 1 · Always use new self-locking nut X Torque specification: Motion sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hand-tight 4 2 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hand-tight Ignition coil bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm 3 C1650130 · · Detach (2) control unit Detach motion sensor (3) 65. 10 Fun audio system Volume control replacement ­ a When installing: · While installation is basically a reversal of the removal process, careful attention should be directed toward the following: Remove instrument trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Group 46 e Attention:take pains to ensure that all wiring is When installing routed correctly!Position to avoid potential rubbing and abrasion! 1 X Torque specification: Volume control attachment . . . . . . . . . . . . . . . . . . . . . hand-tight C1650150 · · Open cable ties (arrows) Disconnect plug (1) 1 C1650140 · · · Open cable tie (arrow) Remove fastener (1) Slide controller forward and remove together with wiring harness 65. 11 Amplifier replacement ­ a Remove the backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Group 52 Mark installed position Speaker removal, installation, replacement · 1 1 C1650160 C1650170 · · Remove fasteners (arrows) Remove front trim (1) toward the front · · · · Remove fasteners (arrows) Slide amplifier to the left behind the vehicle frame and then extract forward to remove Disconnect plug (1) When installing: While installation is basically a reversal of the removal process, careful attention should be directed toward the following: e Attention:take pains to ensure that amplifier is When installing positioned correctly and that all wiring is routed as specified! [. . . ]