BMW C1 Operating instructions

Repair Manual
BMW AG Motorcycle Division
After Sales
C1

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

Introduction
This repair manual will help you to perform all the main maintenance and repair work correctly and efficient-
ly. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and prac-
tical knowledge acquired at the BMW Training Centre. It is a contribution towards achieving even higher
Service quality.
A new issue of this repair manual will be published if amendments or additions (supplements) are needed.
All information in both text and illustrations refers to motorcycles in standard condition or with genuine
BMW accessories installed, and not to motorcycles which have been modified in any way to depart from
the manufacturer’s specification.
•The repair manual is structured in the logical sequence of the work to be performed: Removal, Disas-
sembly,Repair, Assembly, Installation.
•The entire contents are divided into individual chapters, corresponding to the Construction Groups.
An arrow symbol followed by the chapter and page numbers is a reference to another chapter,
e.g. Ób ............................................See Group 46
•Work to be performed during an Inspection is described in Group “00”. The various inspection routines
are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that
work can take place without interruption.
•Use of the BMW special tools needed for certain tasks is described in the work instructions.
If the need arises, repair instructions are also issued in the form of Service Information. This information is
of course incorporated into the next issue of the repair manual. We also recommend, as an additional sour-
ce of information, the Electronic Parts Catalogue (ETC), which contains clear and easy-to-follow illustrati-
ons.
If the work described here is restricted to a particular equipment specification, for instance if a specific op-
tional extra (OE) is fitted, this is stated in square brackets at the start of the item concerned, e.g. [With heat-
ed handlebar grips].
Please refer to the following pages as well for a description of other symbols used and how to work with it.
BMW AG, Motorcycle Division
After Sales
Published by: BMW AG Sparte Motorrad
After Sales
UX-VS-2
D - 80788 München
All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written
permission.
Errors and omissions excepted; subject to technical amendment.
Produced in Germany
11 10.
Chapter Page number within chapter

Usage
Each chapter starts with the list of contents.
The list of contents is followed by the Technical Data table.
Chapter 00 “Maintenance and general instructions”details the handover checklist and lists all tightening
torques and operating fluids.
Key to symbols
In this Workshop Manual for the C 1 model, the following symbols are used; their meanings are explained
in the table.
Special instructions aimed at improving the work procedures.
LNote:
Specific information on operating, inspecting and adjusting work for the motorcycle as well as maintenance
procedures.
eCaution:
Instructions and precautions specifically intended to prevent damage to the motorcycle. Failure to comply
with them could invalidate the warranty.
dWarning:
This symbol stands for precautions and measures which are essential in order to protect the rider or other
persons from possibly severe or fatal injury.
Contents
Headlines for the work described in the chapter................. with the relevant page number
Activities
•Activities
•The bullet symbol means that work steps are described in greater detail under another headline
–Preceding activities
–A line indicates work steps described in greater detail under another headline or in another chapter
If the term “release”or “remove”is used:
the fastener (e.g. screw) must be slackened off and taken out
or
a component (e.g. fuel rail) must be removed to the extent that other components which it conceals (e.g.
throttle-valve rail) are accessible
If the term “loosen”or “slacken”is used:
the fastener (e.g. screw) must only be slackened off but not taken out
X Tightening torques:
Values are stated if they differ from DIN EN 24 014 or DIN 912 ISO industrial standards.

Contents
Group / Chapter Page
00 Maintenance and general instructions ................................................... 00.1
11 Engine ............................................................................................ 11.1
12 Engine electrics ..................................................................................... 12.1
13 Fuel preparation and control.................................................................. 13.1
16 Fuel tank and lines................................................................................. 16.1
17 Radiator ............................................................................................ 17.1
18 Exhaust system ..................................................................................... 18.1
31 Front forks ............................................................................................ 31.1
32 Steering ............................................................................................ 32.1
33 Rear wheel drive.................................................................................... 33.1
34 Brakes ............................................................................................ 34.1

Contents
Group / Chapter Page
36 Wheels and tyres................................................................................... 36.1
46 Frame ............................................................................................ 46.1
51 Equipment ............................................................................................ 51.1
61 General electrical equipment ................................................................. 61.1
62 Instruments ........................................................................................... 62.1
63 Lights ............................................................................................ 63.1
72 Seat belts ............................................................................................ 72.1

Order No. 01 71 0 010 174 UX-VS-2, November 1999 Printed in Germany
Customer Licence plate No.
Order No. Mechanic's signature
BMW
Pre-delivery check
Check the shipping pallet for damage
C1:
–Unpack
–Inspect for damage
–Install remaining items
–Clean
Battery:
–Remove
–Fill with acid
–Charge
–Grease terminal posts
–Install (mark with installation date)
Check that the delivery is complete:
–Toolkit
–Documentation
–Motorcycle keys
–Optional extras
Check tyre pressures
Fill fuel tank
Final inspection as functional check:
–Engine idle
–Clutch, engagement at pull-away
–Steering
Seat belts
Easy-lift
–Front and rear brakes
–Lights and signalling equipment, telltale and warning lights, instruments
–Adjust headlight beam
–If necessary, test ride
BMW AG Motorcycle Division
Pre-delivery check
C1

Order No. 01 71 0 010 174 UX-VS-2, November 1999 Printed in Germany
Customer Licence plate No.
Order No. Mechanic's signature
BMW Inspection at 1,000 km (600 miles) BMW Service 7,500 km (4,500 miles) BMW Inspection every 15,000 km (9,000 miles) BMW Annual Service
MoDiTeC, read fault code memory
Renew the oil filter element
Change the engine oil while at regular operating temperature; renew the oil filter element
If the C1 is ridden only for short distances or at outside temperatures below 0°C, this task must be performed every
3 months, or at least every 3,000 km (1,800 miles)
Clean oil strainer and the magnetic oil drain plug
Change gearbox oil every 30,000 km (18,000 miles)*)30,000 3
Check the coolant level and restore to correct level if necessary, check hoses for damage and chaffing
Change coolant (every two years) 2
Check valve clearances, adjust if necessary*)
Renew the spark plug
In very dirty and dusty operating conditions, replace air-filter element at more frequent intervals
Empty drain pipe from air manifold
Brake hoses and connections: check condition and routing
Check operation of brake system and check for leaks; repair/replace as necessary*)
Check brake fluid level at front and rear
Examine brake pads and discs for wear, replace if necessary*)
Change brake fluid at least once a year*)
Replace variator belt
Check clutch liner, replace if necessary*)
Clean strainer (filter) of variator
Grease driving variator
Replace driving variator assembly every 22,500 km (13,500 miles) 22,500
Check wheel bearings for play, replace if necessary*)
Check that leading link bearing has zero play
Battery: Check battery acid level, if necessary add distilled water
Clean and grease the battery terminals, if necessary
Check Bowden cables (for damage, chaffing and stiff action)
Easy-lift mechanism: check operation of mechanism and check freedom of movement
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 Bowden cable of release, belt buckles, belt webbing, inertia reels, belt stop
Check crash element for damage
Check shoulder bars for damage; replace deformation element if necessary*)
Replace fuel filter (every 37,500 km/22,500 miles) 37,500
Replace rubber element of master brake cylinder ABS, initially complete fitting
(every 30,000 km/18,000 miles) 30,000
Check security of screws and nuts of engine mounts and quick-release axles
Final inspection with road safety and functional check:
– Clutch engagement at pull-away, steering, brakes front and rear, condition of tyres and wheel rims, tyre
pressures
– Lights and signalling equipment, telltale and warning lights, instruments
–Ifnecessary,testride
*)To be billed as separate items, associated work: see brochure on flat-rate units motorcycle 2000
BMW AG Motorcycle Division
Maintenance schedule
C1

Order No. 01 71 0 010 244 UX-VS-2, 11.99 Printed in Germany
Item Desired value Unit of
measurement/
specification
Oil capacities
Engine (with filter)
Gearbox
1.0 (1.76)
0.090 (0.16)
litres (Imp. pints)
15W40
litres (Imp. pints)
API GL 4
Coolant
Cooling system
Expansion tank
1.2 (2.11)
0.2 (0.35)
litres (Imp. pints)
litres (Imp. pints)
Composition:
Water: 50%
Antifreeze: 50%
Antifreeze protection
to –25 °C
Windcreen-washer fluid 1.0 (1.76) Water and cleaning agent;
antifreeze as necessary
Brake fluid DOT 4
Valve clearances
Measured cold (max. 35 °C)
Inlet: 0.05-0.14
(0.002-0.006)
Exhaust: 0.20-0.29
(0.008-0.011)
mm (in)
mm (in)
Spark plug
Electrode gap 0.7...0.8
(0.027...0.031)
NGK CR8 EB
mm (in)
Idle speed 1,900 rpm
Tyre pressure (cold tyres)
solo
fully loaded
front/rear
1.9/2.1 (27.6/30.5)
1.9/2.4 (27.6/34.8)
bar (psi)
bar (psi)
Tightening torques:
Engine oil drain plug
Oil mesh filter on engine
Engine water drain plug
Oil filter cap
Camshaft sprockets to camshafts
Guide rail to camshaft mount
Screw plug for chain tensioner
Camshaft bearing cap
Valve cap
Machine screw for locating crankshaft at TDC
Spark plug
Variator, driving
Cover for driving variator
Variator, driven
Locknut, clutch to driven variator
Variator cover to drive swinging arm
Ventilation cover for variator
Front quick-release axle
Clamping screws for front quick-release axle
Brake calliper at fork slider tube
Bleed screw in brake calliper
Cover of handbrake fitting
Rear quick-release axle Never re-use nut
Exhaust to cylinder head
Secondary swinging arm to drive swinging arm, M8
Secondary swinging arm to drive swinging arm, M10
Silencer to secondary swinging arm
Spring strut to drive swinging arm/brake calliper holder
Swinging-arm bearing to drive swinging arm
Tubular swinging arm to frame
Stand to frame
Rubber element to tubular swinging arm
Screws for trim panels
20
30
10
10
30
10
35
10
10
15
15
60
4
60
50
10
9
83
21
41
14
Hand-tight
130
15
21
60
21
21
73
73
41
42
5
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 (Loctite 243)
Nm
Nm
Nm
Nm
Nm
Nm
Nm
Nm (Loctite 243)
Nm
Nm
Nm
Nm
Nm
Nm
Nm
BMW AG Motorcycle Division
Service data
C1

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

00.2
Contents - Instructions for handover to customer Page
Check the shipping pallet for damage ............................................................................29
In case of damage in Germany ...............................................................................................29
In case of damage in importer markets ..............................................................................29
Unpacking the C1 .......................................................................................................................30
Filling and charging the battery ..........................................................................................33
Checking the C1 for damage ...............................................................................................34
Checking that delivery is complete ..................................................................................34
Reading the fault code memory with the BMW MoDiTeC/DIS plus ................34
Checking tyre pressures ........................................................................................................34
Fuelling .............................................................................................................................................35
Final inspection and function check ................................................................................35
Final cleaning ...............................................................................................................................35
Handing over the vehicle ........................................................................................................36
Instructions for handover to customer

00.3
Contents - Maintenance Page
Key to maintenance intervals ..............................................................................................37
Reading out MoDiTeC/DIS plus fault memory ............................................................37
(Inspections I, II, III and IV) ................................................................................................................37
Engine oil change .......................................................................................................................38
(Inspections I, II, III and IV) ................................................................................................................38
Cleaning oil strainer and magnetic plug ........................................................................38
(Inspections I, II, III and IV) ................................................................................................................38
Changing gearbox oil ...............................................................................................................38
(Inspections II and III) ........................................................................................................................38
Checking coolant ..........................................................................................................................39
Adding coolant .................................................................................................................................39
Changing coolant .......................................................................................................................40
(Inspection IV) every 2 years .............................................................................................................40
Draining coolant ...............................................................................................................................40
Draining expansion tank ...................................................................................................................40
Adding coolant .................................................................................................................................40
Checking valve clearances ...................................................................................................41
(Inspections I, II and III) .....................................................................................................................41
Moving drive swinging arm clear ...........................................................................................41
Checking valve clearances ...................................................................................................43
(Inspections I, II and III) .....................................................................................................................43
Adjusting valve clearances .......................................................................................................44
Removing and installing camshaft bearing cap/camshaft .................................................................45
Replacing spark plug ...............................................................................................................46
(Inspections III) .................................................................................................................................46
Renewing air cleaner element ............................................................................................47
(Inspections II and III) ........................................................................................................................47
Emptying drain pipe from air manifold ...........................................................................47
(Inspections I, II, III and IV) ................................................................................................................47
Checking brake lines ................................................................................................................48
(Inspections II and III) ........................................................................................................................48
Checking brake lines ........................................................................................................................48
Checking brake system for correct operation and freedom from leaks ......48
(Inspections II and III) ........................................................................................................................48
Checking brake fluid level .....................................................................................................48
Checking fluid level with brake fluid reservoir closed ...................................................48
Checking fluid level with brake fluid reservoir open ......................................................49
Checking brake pads and discs for wear/replacing ...............................................50
Maintenance

00.4
Contents - Maintenance Page
Checking brake pads for wear ................................................................................................50
Front brake pads ..............................................................................................................................50
Rear brake pads ...............................................................................................................................50
Replacing brake pads .................................................................................................................51
Front brake .......................................................................................................................................51
Rear brake ........................................................................................................................................52
Checking the brake discs .........................................................................................................53
Renewing brake fluid ................................................................................................................53
(Inspection IV) ...................................................................................................................................53
Front brake .......................................................................................................................................54
Drawing off brake fluid/forcing back brake pistons ............................................................................54
Bleeding the front brake circuit .........................................................................................................54
Rear brake ........................................................................................................................................55
Drawing off brake fluid/forcing back brake pistons ............................................................................55
Bleeding rear brake circuit ................................................................................................................55
Replacing variator belt ............................................................................................................56
(Inspections II and III) ........................................................................................................................56
Checking belt .................................................................................................................................56
Checking clutch lining .............................................................................................................57
Cleaning mesh filter of variator ..........................................................................................58
(Inspections II and III) ........................................................................................................................58
Greasing driving variator ........................................................................................................58
(Inspections II and III) ........................................................................................................................58
Replacing complete driving variator ................................................................................59
(Inspection III) every 22,500 km (13,500 miles) ..................................................................................59
Checking wheel bearing play ..............................................................................................60
(Inspections I, II and III) .....................................................................................................................60
Checking telescopic forks and all spring struts for leaks ...................................60
(Inspections II and III) ........................................................................................................................60
Checking locks ............................................................................................................................60
(Inspection IV) ...................................................................................................................................60
Checking that leading-link mounts are free of play ................................................61
(Inspections I, II, III and IV) ................................................................................................................61
Checking steering bearing play ........................................................................................................61
Checking battery acid level, adding distilled water if necessary ....................61
(Inspections II, III and IV) ...................................................................................................................61
Checking battery acid level ......................................................................................................61
Adding distilled water .......................................................................................................................62
Cleaning and greasing the battery terminals, if necessary ................................62
(Inspections III and IV) ......................................................................................................................62

00.5
Contents - Maintenance Page
Checking Bowden cables ......................................................................................................62
(Inspections I, II, IV) ..........................................................................................................................62
Bowden cable for easy-lift: ...............................................................................................................62
Throttle cable: ..................................................................................................................................62
Checking headlight beam angle ........................................................................................62
(Inspection IV) ...................................................................................................................................62
Checking windscreen washer .............................................................................................63
(Inspections I, II, III and IV) ................................................................................................................63
Checking windscreen wiper .................................................................................................63
(Inspections II, III and IV) ...................................................................................................................63
Checking safety elements .....................................................................................................64
(Inspections I, II, III and IV) ................................................................................................................64
Checking Bowden cable of central seat-belt release ...................................................64
Checking belt straps and belt buckles ................................................................................64
Checking inertia reels .................................................................................................................64
Checking inertia-reel locking action .....................................................................................64
Examining crash element .......................................................................................................65
Checking shoulder bars and deformation element .................................................65
Checking body panels and fairing ....................................................................................65
(Inspection IV) ...................................................................................................................................65
Replacing fuel filter ...................................................................................................................66
(Inspection III) every 37,500 km (22,500 miles) ..................................................................................66
Replacing rubber diaphragm of brake master cylinder (30,000 km/
18,000 miles)
Vehicles with ABS only ............................................................................................................67
Checking security of threaded fasteners ......................................................................68
(Inspections I, II, III and IV) ................................................................................................................68
Final inspection with road safety and functional check .......................................68
(Inspections I, II, III and IV) ................................................................................................................68
Tyre tread depth (recommended minimum value) ..............................................................................68
Tyre pressures (tyres cold) ................................................................................................................68
Roadworthiness check .....................................................................................................................68

00.6

00.7
00
Tightening torques
Model C1
Connection Nm
11 Engine
Oil drain plug, magnetic 20
Threaded plug, oil strainer 30
Oil filter cover 10
Threaded plug for locking at TDC 15
Alternator
Alternator cover 10
Ignition trigger, Tapite screw 6 Loctite 243
Holder for alternator cable, Tapite screw 6 Loctite 243
Magnetic rotor to crankshaft, thread-locking
compound 30 Loctite 243
Fastener for freewheel, thread-locking com-
pound 30 Loctite 243
Alternator to cover 10
Chain tensioning rail, thread-locking com-
pound 10 Loctite 243
Variator
Ventilation cover for variator 9
Variator cover 10
Driving variator, thread-locking compound 60 Loctite 243
Cover, driving variator 4
Driven variator (clutch drum) 60
Locknut of driven variator, thread-locking
compound 50 Loctite 243
Gearbox
Gearbox cover 11
Drain plug for gearbox oil 20
Filler plug for gearbox oil 5

00.8
Cylinder head
Cylinder head cover 10
Collar nut 30 ±1
Securing screw 10
Spark plug 15
Camshaft gears, thread-locking compound 30 Loctite 243
Bearing cap 10
Chain guide, thread-locking compound 10 Loctite 243
Plug for chain tensioner 35
Vent screw 9
Dual temperature sensor, thread-locking
compound 15 Loctite 243
Housing
Starter motor 10
Oil-pressure switch, thread-locking com-
pound 12 Loctite 243
Oil pressure valve 30
Stud (tie bolt) 10
Housing screws 10
Oil pump, Tapite screw 6 Loctite 243
Water-pump housing, Tapite screw 6 Loctite 243
Model C1
Connection Nm

00.9
12 Engine electrics
Spark plug 15
Ignition coil to frame 5
Model C1
Connection Nm

00.10
13 Fuel preparation and control
Fastener, fuel filter clamp 5
Holder for injection nozzle (self-tapping) 4 Loctite 243
Pressure regulator clamp 9
BMS control unit 5
Intake manifold 9
Air filter housing (inner/outer) 9
Fastener for throttle cable 8
Model C1
Connection Nm