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 7 644, to press outer plate onto inner plate Coat guide sleeves and guide pin with grease and insert into 3 recesses in secondary outer plate 11 7 642 L Note:not to damage O-rings!Take care · Slide on guide cover and position on stud in outside plate Fluids and lubricants: Shell Retinax HDX2 . . . . . . . . . . . . . . 4. . . 5 g (0. 14. . . 0. 18 oz) ­ Installing clutch (a 21. 7) C1110631 · · Use hand press and assembly press, BMW No. 11 7 642, to press in needle bearing (4) Check inside diameter of outside plate and inspect guide groove for wear Wear data: Inside Ø. . . . . . . . . . . . . . . . . . . . . . . . . . min. 34. 05 mm (1. 3406 in) 24. 17 Variator - reduction gear unit 23 21 200 When installing: Replace shaft oil seal for variator shaft in gearbox cover (shaft installed) e Attention:shaft oil seals Spray seats of 11 7 571 For the sake of clarity, these illustrations show the vehicle with the powertrain cradle removed. ­ Removing driven variator (a 24. 6) C1110670 · C1110660 Uniformly chamfer collar at cover e Attention:shaft oil seal and remove metal chipDeburr seat for pings! · Use screwdriver as a lever to carefully prise out shaft oil seal · · Install shaft oil seal with tube, BMW No. 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 Shaft 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm Gearbox cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. [. . . ] 2 Nm Torque specification: Front Replacing left/right speaker brackets The following section provides a portrayal of the procedural sequence to pursue when extracting the speaker located upon the left side of this vehicle. The operations for the bracket on the right side are essentially the same. ­ C1650190 · Speaker removal Remove rubber grommets e Attention:in the groove (arrows) of the bracket Insert speaker on the left!Route to avoid rubbing and abrasion! X Torque specification:. . . . . . . . . . . . . . . . . . . . . . . . . . [. . . ]