![BMW C1 (2001) [118/458] Piston removal installation replacement](/img/pdf.png)
BMW C1 (2001) [118/458] Piston removal installation replacement
![BMW C1 (2001) [118/458] Piston removal installation replacement](/views2/1121050/page118/bg76.png)
11.42
When installing:
L
Note:
Always install with new seal!
•
Secure crankshaft at TDC (
a
11.14)
•
Use ring squeezer sleeve
C1:
BMW No. 11 7 632
C1 200:
BMW No. 11 7 633
L
Note:
Do not damage the piston!
•
Slide cylinder over the piston
•
Carefully slip sleeve up and to one side to re-
move
Replacing stud bolts
– Removing cylinder
•
Use vise grips to remove studs
When installing:
X
Torque specification:
Stud ............................................................. 10 Nm
11 25 050
Piston removal, installation,
replacement
– Removing cylinder
•
Remove circlip
11 7 632
C1111000
11 7 633
C1111010
C1111020
Содержание
- Preface 3
- Contents 4
- Explanation of symbols 4
- How to use this manual 4
- Operations 4
- Contents 5
- Continuation 6
- Bmw annual service 7
- Bmw inspection at 10 00 km 600 miles 7
- Bmw inspection every 15 000 km 9 000 miles 7
- Bmw maintenance service every 7 500 km 4 500 miles 7
- Bmw motorrad maintenance schedule c1 c1 200 7
- Bmw motorrad pre delivery check c1 c1 200 8
- Bmw motorrad service data c1 c1 200 9
- Item specified value 9
- Unit of measure or specification 9
- Brakes 11
- Clutch 11
- Contents 11
- Cooling system 11
- Electrical equipment 11
- Engine 11
- Engine electrical system 11
- Equipment 11
- Final drive unit 11
- Front forks 11
- Fuel injection system 11
- Fuel tank 11
- Gearbox 11
- Instruments 11
- Lights 11
- Optional extras 11
- Seat belts 11
- Silencer muffler 11
- Steering 11
- Table of service products 11
- Tightening torques operating fluids 11
- Torque specifications 11
- Wheels 11
- Torque specifications 13
- Table of service products 22
- Add fuel 25
- Check c1 for damage 25
- Check package contents to determine whether consignment is complete 25
- Check transport container for damage 25
- Check tyre inflation pressures 25
- Contents 25
- Damage in export markets 25
- Damage in germany 25
- Fill and charge the battery 25
- Final cleaning 25
- Operation check as final inspection 25
- Pre delivery check 25
- Unpack c1 25
- Use bmw moditec dis plus to access stored error codes 25
- Vehicle delivery 25
- Check transport container for dam age 27
- Damage in export markets 27
- Damage in germany 27
- Unpack c1 28
- Check c1 for damage 33
- Check package contents to deter mine whether consignment is com plete 33
- Fill and charge the battery 34
- Add fuel 35
- Check tyre inflation pressures 35
- Operation check as final inspection 35
- Use bmw moditec dis plus to access stored error codes 35
- Final cleaning 36
- Vehicle delivery 36
- Adjusting valve clearances 37
- Change coolant 37
- Checking brake lines 37
- Checking brake system operation and inspect for leaks 37
- Checking coolant 37
- Checking valve clearances 37
- Contents 37
- Empty drain pipe from intake air plenum chamber 37
- Engine oil change 37
- Gearbox oil change 37
- Maintenance 37
- Maintenance intervals 37
- Reading out bmw moditec dis and error codes stored in ecu 37
- Replace spark plug 37
- Replacing air cleaner element 37
- Swivel out powertrain cradle 37
- Check and clean drive variator unlubricated version 38
- Check belt 38
- Check clean and grease drive variator lubricated version 38
- Checking brake fluid level 38
- Checking brake pads and discs for wear replacing 38
- Checking brake pads for wear 38
- Checking clutch lining 38
- Checking fluid level in the closed brake fluid reservoir 38
- Checking fluid level in the open brake fluid reservoir 38
- Checking the brake discs 38
- Checking wheel bearing float 38
- Clean variator filter screen 38
- Contents 38
- Drive variator 38
- Front brake 38
- Rear brake 38
- Remove drive variator 38
- Replacing brake fluid 38
- Replacing brake pads 38
- Replacing complete drive variator 38
- Variator drive belt replacement 38
- Check battery electrolyte level add distilled water if necessary 39
- Check belt straps and belt buckles 39
- Check bowden cable for central seat belt release 39
- Check inertia reel s detent mechanism to ensure that it engages correctly 39
- Check inertia reels 39
- Check mounts 39
- Check shoulder bar and deformation element 39
- Check to ensure that leading link bearing has zero play 39
- Check windscreen wiper 39
- Checking battery electrolyte level 39
- Checking bowden cables 39
- Checking safety elements 39
- Checking windscreen washer 39
- Clean grease battery terminals if necessary 39
- Contents 39
- Examine crash elements 39
- Final inspection with road safety and operation check 39
- Measure shoulder bar 39
- Replacing boot in brake control assembly master cylinder only with optional abs 39
- Replacing fuel filter 39
- Maintenance intervals 41
- Reading out bmw moditec dis and error codes stored in ecu 41
- Engine oil change 42
- Gearbox oil change 43
- Checking coolant 44
- Change coolant 45
- Checking valve clearances 46
- Swivel out powertrain cradle 46
- Checking valve clearances 48
- Adjusting valve clearances 49
- Replace spark plug 52
- Empty drain pipe from intake air plenum chamber 53
- Replacing air cleaner element 53
- Checking brake fluid level 54
- Checking brake lines 54
- Checking brake system operation and inspect for leaks 54
- Checking fluid level in the closed brake fluid reservoir 54
- Checking fluid level in the open brake fluid reservoir 55
- Checking brake pads and discs for wear replacing 56
- Checking brake pads for wear 56
- Replacing brake pads 57
- Checking the brake discs 59
- Front brake 60
- Replacing brake fluid 60
- Rear brake 61
- Variator drive belt replacement 62
- Check belt 63
- Checking clutch lining 64
- Clean variator filter screen 64
- Check clean and grease drive variator lubricated version 65
- Drive variator 65
- Remove drive variator 65
- Check and clean drive variator unlu bricated version 67
- Replacing complete drive variator 68
- Checking wheel bearing float 69
- Check battery electrolyte level add distilled water if necessary 70
- Check to ensure that leading link bearing has zero play 70
- Checking battery electrolyte level 70
- Checking bowden cables 71
- Checking easy lift mechanism 71
- Clean grease battery terminals if necessary 71
- Check belt straps and belt buckles 72
- Check bowden cable for central seat belt release 72
- Check inertia reel s detent mechanism to ensure that it engages correctly 72
- Check inertia reels 72
- Check windscreen wiper 72
- Checking safety elements 72
- Checking windscreen washer 72
- 13 3 010 13 3 010 73
- Check shoulder bar and deforma tion element 73
- Examine crash elements 73
- Measure shoulder bar 73
- Replacing fuel filter 73
- Replacing boot in brake control assembly master cylinder only with optional abs 74
- Check mounts 75
- Final inspection with road safety and operation check 75
- Adjusting valve clearances 77
- Bucket tappet removal installation replacement 77
- C1 drivetrain 77
- C1 engine 77
- C1 lubrication 77
- Checking valve clearances 77
- Contents 77
- Cylinder head 77
- Dual temperature sensor removal installation replacement 77
- Engine 77
- Lock engine at tdc 77
- Operations performed with powertrain cradle installed 77
- Removing and installing powertrain cradle 77
- Replacing filter screen 77
- Replacing grooved ball bearing for engine mount 77
- Replacing ignition cover 77
- Replacing oil filter 77
- Replacing oil pressure switch 77
- Replacing oil pump 77
- Replacing oil seal on crankshaft 77
- Replacing pressure relief bypass valve 77
- Swivel out powertrain cradle 77
- Technical data 77
- Water pump removal installation replacement 77
- Camshaft camshaft sprocket camshaft bearing cap 78
- Check timing chain 78
- Contents 78
- Cylinder head cover removal and installation 78
- Cylinder head removal and installation 78
- Inlet and exhaust valve 78
- Joining halves of crankcase 78
- Measuring housing 78
- Measuring main bearings 78
- Piston removal installation replacement 78
- Removing crankshaft 78
- Replacing bearing shells 78
- Replacing chain rails 78
- Replacing chain tensioner 78
- C1 engine 85
- C1 lubrication 86
- C1 drivetrain 87
- Operations performed with power train cradle installed 88
- Swivel out powertrain cradle 88
- Lock engine at tdc 90
- Checking valve clearances 91
- Adjusting valve clearances 92
- Removing and installing powertrain cradle 93
- Replacing grooved ball bearing for engine mount 95
- Replacing ignition cover 95
- Replacing oil pump 96
- Water pump removal installation replacement 97
- Replacing oil filter 100
- Replacing oil pressure switch 100
- Replacing pressure relief bypass valve 100
- Replacing filter screen 101
- Replacing oil seal on crank shaft 101
- Bucket tappet removal installation replacement 102
- Cylinder head 102
- Dual temperature sensor removal installation replacement 102
- Inlet and exhaust valve 103
- Check timing chain 109
- Replacing chain tensioner 109
- Cylinder head cover removal and installation 110
- Camshaft camshaft sprocket camshaft bearing cap 111
- Replacing chain rails 114
- Cylinder head removal and installation 116
- Piston removal installation replacement 118
- Removing crankshaft 121
- Ii ii iii iii 122
- Measuring housing 122
- Measuring main bearings 122
- Replacing bearing shells 122
- Joining halves of crankcase 125
- Contents 127
- Engine electrics 127
- Reluctor removal and installation 127
- Replacing alternator 127
- Replacing ignition cable 127
- Replacing ignition coil 127
- Replacing spark plug ignition cable 127
- Replacing spark plugs 127
- Replacing starter 127
- Replacing tdc trigger 127
- Technical data 127
- Replacing spark plug igni tion cable 131
- Replacing spark plugs 131
- Replacing ignition cable 132
- Replacing ignition coil 132
- Replacing alternator 133
- Replacing starter 133
- Reluctor removal and installation 134
- Replacing tdc trigger 134
- Contents 139
- Fuel preparation and control 139
- Injector 139
- Removing and installing air filter housing 139
- Removing and installing intake air plenum chamber 139
- Removing and installing throttle valve assembly 139
- Replacing bms control unit 139
- Removing and installing air filter housing 141
- Removing and installing intake air plenum chamber 141
- Removing and installing throttle valve assembly 143
- Injector 144
- 3 010 17 5 500 145
- Replacing bms control unit 145
- Contents 147
- Fuel pump unit 147
- Fuel tank and lines 147
- Removing and installing fuel tank 147
- Removing installing fuel pump assembly 147
- Replacing fuel filter 147
- Technical data 147
- Removing and installing fuel tank 151
- Replacing fuel filter 153
- 13 3 010 13 3 010 154
- Fuel pump unit 154
- Removing installing fuel pump assembly 154
- Adding coolant 157
- Changing coolant 157
- Checking cooling system for leaks 157
- Closing hose clamps 157
- Contents 157
- Coolant circuit 157
- Draining coolant 157
- Installing coolant hoses 157
- Installing coolant pipes 157
- Opening hose clamps 157
- Radiator 157
- Removing and installing coolant hoses 157
- Removing and installing coolant pipes 157
- Removing and installing expansion tank 157
- Removing engine coolant feed pipe 157
- Removing engine coolant return pipe 157
- Replacing coolant hoses on engine 157
- Replacing feed hoses to radiator 157
- Replacing return hose to radiator 157
- Replacing vapour discharge hose 157
- Technical data 157
- Contents 158
- Removing and installing front frame with radiator 158
- Removing and installing radiator with fan 158
- Removing and installing radiator with fan shroud in front frame 158
- Replacing air duct 158
- Replacing fan 158
- Replacing radiator 158
- Replacing refill reservoir 158
- Coolant circuit 161
- Closing hose clamps 163
- Opening hose clamps 163
- Removing and installing coolant hoses 163
- Replacing feed hoses to radia tor 163
- Installing coolant hoses 164
- Replacing return hose to radi ator 164
- Replacing coolant hoses on engine 165
- Removing and installing coolant pipes 166
- Removing engine coolant feed pipe 166
- Installing coolant pipes 167
- Removing engine coolant return pipe 167
- Replacing vapour discharge hose 168
- Removing and installing expansion tank 169
- Changing coolant 170
- Draining coolant 170
- Adding coolant 171
- Checking cooling system for leaks 172
- Removing and installing front frame with radiator 173
- Removing and installing radiator with fan 173
- Removing and installing radiator with fan shroud in front frame 174
- Replacing air duct 175
- Replacing fan 175
- Replacing radiator 175
- Replacing refill reservoir 176
- Contents 177
- Exhaust system 177
- Removing and installing oxygen sensor 177
- Removing and installing silencer heat shield 177
- Removing and installing silencer system 177
- Technical data 177
- Removing and installing silencer heat shield 181
- Removing and installing silencer system 181
- Removing and installing oxy gen sensor 183
- Centrifugal coupling 185
- Check spring 185
- Checking clutch 185
- Clutch 185
- Contents 185
- Install clutch 185
- Removing replacing clutch 185
- Technical data 185
- Centrifugal coupling 189
- Checking clutch 189
- Removing replacing clutch 189
- Check spring 190
- Install clutch 191
- C1 gearbox 193
- Checking individual components 193
- Checking individual components of driven variator 193
- Contents 193
- Disassembling checking and assembling drive variator 193
- Dismantling and assembling gearbox checking individual components 193
- Dismantling drive variator 193
- Dismantling testing and assembling drive variator 193
- Gearbox 193
- Inspect individual components of drive variator 193
- Installing variator 193
- Operations with powertrain cradle installed 193
- Removing variator 193
- Replace shaft oil seal for variator shaft in gearbox cover shaft installed 193
- Technical data 193
- Variator reduction gear unit 193
- Variator replacement 193
- Checking dimensions of gearbox shafts 194
- Contents 194
- Gearbox cover removal 194
- Gearbox shaft removal 194
- Replacing housing shaft oil seal on output shaft 194
- Replacing shaft oil seal for variator shaft in gearbox cover shaft removed 194
- C1 gearbox 197
- Operations with powertrain cradle installed 198
- Removing variator 198
- Variator replacement 198
- Installing variator 200
- Disassembling checking and assembling drive variator 202
- Dismantling drive variator 202
- Inspect individual components of drive variator 203
- Checking individual components of driven variator 206
- Dismantling testing and assembling drive variator 206
- Checking individual components 207
- Replace shaft oil seal for varia tor shaft in gearbox cover shaft installed 210
- Variator reduction gear unit 210
- Dismantling and assembling gearbox checking individual compo nents 211
- Gearbox cover removal 212
- Gearbox shaft removal 212
- Replacing housing shaft oil seal on output shaft 213
- Replacing shaft oil seal for variator shaft in gearbox cover shaft removed 214
- Checking dimensions of gearbox shafts 218
- Contents 221
- Dismantling fork cross brace 221
- Fork cross brace components 221
- Front forks 221
- Installing fork cross brace 221
- Installing telescopic fork 221
- Installing telescopic tube cross brace with telescopic tubes 221
- Removing and installing fixed tube 221
- Removing and installing telescopic forks and fork cross brace 221
- Removing fork cross brace 221
- Removing telescopic fork 221
- Removing telescopic tube cross brace with telescopic tubes 221
- Replace guide bush 221
- Replace seal telescopic tube seal holder 221
- Replacing ball joint 221
- Replacing seal rings for telescoping tube 221
- Replacing telescopic tube 221
- Replacing telescopic tube cross brace 221
- Replacing telescopic tube seal 221
- Technical data 221
- Checking runout of fixed tube 222
- Contents 222
- Examining telescoping tube cross brace and fork cross brace 222
- Installing leading link 222
- Measuring telescopic fork 222
- Removing and installing front spring strut 222
- Removing and installing leading link 222
- Removing leading link 222
- Replacing left and right taper fit ball bearings for leading link 222
- Replacing spring shock absorber 222
- Removing and installing telescopic forks and fork cross brace 225
- Removing telescopic fork 225
- Removing and installing fixed tube 226
- Removing fork cross brace 227
- Dismantling fork cross brace 228
- Fork cross brace components 228
- Installing fork cross brace 230
- Installing telescopic fork 231
- Removing telescopic tube cross brace with telescopic tubes 231
- Replacing seal rings for tele scoping tube 231
- Replacing telescopic tube seal 233
- Replace seal telescopic tube seal holder 234
- Replace guide bush 235
- Replacing telescopic tube 236
- Replacing telescopic tube cross brace 237
- Installing telescopic tube cross brace with telescopic tubes 238
- Replacing ball joint 238
- Checking runout of fixed tube 239
- Examining telescoping tube cross brace and fork cross brace 239
- Measuring telescopic fork 239
- Removing and installing front spring strut 239
- Removing and installing leading link 243
- Removing leading link 243
- Replacing spring shock absorber 243
- 2 4 6 5 1 7 244
- A b c d 2 244
- A b c d 6 244
- Installing leading link 245
- Replacing left and right taper fit ball bearings for leading link 245
- Contents 247
- General view of handlebar 247
- Heated grip removing and installing on left side 247
- Heated grip removing and installing on right 247
- Heated grips 247
- Removing and installing handlebar 247
- Removing and installing left and right handlebar levers 247
- Removing and installing left right brake control assemblies 247
- Replacing left right brake lamp switch 247
- Replacing seal in brake unit master cylinder with optional abs only 247
- Replacing throttle cable 247
- Steering 247
- Technical data 247
- General view of handlebar 251
- Heated grip removing and installing on left side 252
- Heated grips 252
- Heated grip removing and installing on right 253
- Removing and installing left right brake control assemblies 254
- Replacing left right brake lamp switch 255
- Replacing seal in brake unit master cylinder with optional abs only 256
- Removing and installing handlebar 257
- Removing and installing left and right handlebar levers 257
- Replacing throttle cable 259
- Auxiliary swing arm 261
- Contents 261
- Installing auxiliary swing arm 261
- Rear wheel drive 261
- Removing and installing left right spring strut 261
- Removing auxiliary swing arm 261
- Replacing silentblocks 261
- Replacing spring shock absorber 261
- Technical data 261
- Auxiliary swing arm 265
- Installing auxiliary swing arm 265
- Removing auxiliary swing arm 265
- Replacing silentblocks 265
- Removing and installing left right spring strut 266
- Replacing spring shock absorber 267
- Brake caliper backplate 269
- Brakes 269
- Checking and adjusting abs wheelspeed sensor gap 269
- Contents 269
- Front abs wheelspeed sensor removal and installation 269
- Front brake caliper 269
- Front wheel 269
- Installing brake caliper carrier 269
- Rear brake caliper 269
- Rear wheel 269
- Removing and installing abs control unit 269
- Removing and installing brake caliper 269
- Removing and installing front brake disc 269
- Removing and installing front brake lines hoses 269
- Removing and installing rear abs sensor 269
- Removing and installing rear brake caliper 269
- Removing and installing rear brake disc 269
- Removing brake caliper carrier 269
- Removing front brake lines hoses with abs 269
- Replacing brake caliper carrier bearing 269
- Replacing front abs reluctor 269
- Replacing front brake hose without abs 269
- Replacing rear abs reluctor 269
- Replacing rubber bush 269
- Technical data 269
- Brake hose between brake line and brake caliper 270
- Brake hose between brake unit on left and brake line 270
- Brake line between brake hose left brake control assembly and brake hose to brake caliper without abs 270
- Brake lines between brake hose left brake control assembly and brake hose to brake caliper with abs 270
- Checking brake fluid level 270
- Checking brake pads and discs for wear replacing 270
- Checking brake pads for wear 270
- Checking fluid level in the closed brake fluid reservoir 270
- Checking fluid level in the open brake fluid reservoir 270
- Checking the brake discs 270
- Contents 270
- Front brake 270
- Installing front brake lines hoses with abs 270
- Rear brake 270
- Removing and installing rear brake lines hoses 270
- Replacing brake fluid and bleeding brake system 270
- Replacing brake pads 270
- Brake caliper backplate 273
- Removing brake caliper car rier 273
- Replacing brake caliper carrier bearing 273
- Replacing rubber bush 274
- Front brake caliper 275
- Installing brake caliper carrier 275
- Removing and installing brake caliper 275
- Rear brake caliper 276
- Removing and installing rear brake caliper 276
- Removing and installing front brake disc 279
- Removing and installing rear brake disc 279
- Front abs wheelspeed sen sor removal and installation 280
- Replacing front abs reluctor 281
- Removing and installing rear abs sensor 282
- Checking and adjusting abs wheel speed sensor gap 283
- Front wheel 283
- Replacing rear abs reluctor 283
- Rear wheel 284
- Removing and installing abs control unit 284
- Removing and installing front brake lines hoses 287
- Replacing front brake hose without abs 287
- R em oving front brake lines hoses w ith ab s 289
- Brake hose betw een brake unit on left and brake line 290
- Installing front brake lines hoses w ith ab s 290
- R em oving and installing rear brake lines hoses 290
- Brake line between brake hose left brake control assembly and brake hose to brake caliper without abs 292
- Brake lines between brake hose left brake control assembly and brake hose to brake caliper with abs 293
- Brake hose between brake line and brake caliper 296
- Checking brake pads and discs for wear replacing 297
- Checking brake pads for wear 297
- Replacing brake pads 298
- Checking the brake discs 300
- Checking brake fluid level 301
- Checking fluid level in the closed brake fluid reservoir 301
- Checking fluid level in the open brake fluid reservoir 302
- Front brake 303
- Replacing brake fluid and bleeding brake system 303
- Rear brake 304
- Checking front rear wheel rim for runout 305
- Checking front wheel rim for runout 305
- Checking rear wheel rim for runout 305
- Contents 305
- Installing rear wheel 305
- Installing right left wheel bearings 305
- Removing and installing front wheel 305
- Removing and installing rear wheel 305
- Removing left right wheel bearings 305
- Removing rear wheel 305
- Replacing wheel bearings 305
- Static balancing of front and rear wheels 305
- Static balancing of front wheel 305
- Static balancing of rear wheel 305
- Technical data 305
- Wheels and tyres 305
- Removing and installing front wheel 309
- Removing left right wheel bearings 311
- Replacing wheel bearings 311
- Installing right left wheel bearings 312
- Removing and installing rear wheel 313
- Removing rear wheel 313
- Installing rear wheel 314
- Static balancing of front and rear wheels 315
- Static balancing of front wheel 315
- Static balancing of rear wheel 315
- Checking front rear wheel rim for runout 316
- Checking front wheel rim for runout 316
- 3 617 36 3 631 317
- Checking rear wheel rim for runout 317
- C pillar foam element removal installation replacement 319
- C pillar inner trim removal installation replacement 319
- C1 trim mount 319
- C1 trim overview 319
- Contents 319
- Crash element removal installation replacement 319
- Crash element trim removal installation replacement 319
- Impact panel removal installation replacement 319
- Instrument trim removal installation and replacement 319
- Knee trim removal installation replacement 319
- Left and right lower panel removal installation replacement 319
- Left right tunnel removal installation replacement 319
- Panel centre section removal installation replacement 319
- Rear side trim removal installation replacement 319
- Rear storage compartment cover 319
- Rear trim removal installation replacement 319
- Removing and installing front trim 319
- Replacing holder for crash element 319
- Running board cover removal and installation 319
- Shoulder bar crash element left or right removal and installation 319
- Shoulder bar external trim removal installation replacement 319
- Side panel removal installation replacement 319
- Technical data 319
- Upper tunnel removal installation replacement 319
- Articulated joint hand lever mechanism removal and installation 320
- Articulated joint mechanism 320
- Bowden cable installation adjustment 320
- Checking shoulder bar alignment 320
- Contents 320
- Cross brace foam element removal installation replacement 320
- Large storage compartment 320
- Licence plate bracket removal installation replacement 320
- Lobe overload guard transfer element replacement 320
- Overview 320
- Rear mudguard removal installation replacement 320
- Removing and installing articulated joint mechanism 320
- Removing bowden cable for extending stand 320
- Removing bowden cable for retracting stand 320
- Removing installing stand 320
- Replace stand bowden cables 320
- Replacing cover 320
- Replacing tension spring s 320
- Replacing the power socket 320
- Roof bar replacement 320
- Roof removal and installation 320
- Shoulder bar replacement 320
- Stand bearings 320
- Storage compartment removal and installation 320
- Windscreen removal and installation 320
- Bracket removal and installation 321
- Contents 321
- Coupling for swing arm bearing 321
- Hinge replacement 321
- Installing powertrain cradle mounts 321
- Luggage hook replacement 321
- Luggage system bracket 321
- Luggage system lock carrier removal and installation 321
- Overview 321
- Powertrain cradle 321
- Rear frame member replacement 321
- Removing powertrain cradle mounts 321
- Replacing inside lock 321
- Replacing stand switch 321
- Support base removal and installation 321
- Topcase 321
- Tubular swing arm 321
- Upper bracket removal and installation 321
- C1 trim overview 325
- C1 trim mount 327
- Removing and installing front trim 327
- Running board cover removal and installation 327
- Left and right lower panel removal installation replacement 328
- Panel centre section removal installation replacement 328
- Rear side trim removal instal lation replacement 329
- Rear storage compartment cover 330
- Upper tunnel removal installa tion replacement 331
- Left right tunnel removal installation replacement 332
- Side panel removal installa tion replacement 333
- C pillar inner trim removal installation replacement 334
- Shoulder bar external trim removal installation replacement 335
- C pillar foam element removal installation replacement 336
- Shoulder bar crash element left or right removal and installation 336
- Rear trim removal installation replacement 337
- Instrument trim removal installation and replacement 338
- Impact panel removal installa tion replacement 339
- Crash element removal instal lation replacement 340
- Crash element trim removal installation replacement 340
- Replacing holder for crash ele ment 340
- Knee trim removal installation replacement 341
- Licence plate bracket removal installation replacement 342
- Rear mudguard removal installation replacement 342
- Large storage compartment 343
- Replacing cover 343
- Storage compartment removal and installation 343
- Replacing the power socket 344
- Roof removal and installa tion 345
- Windscreen removal and installation 345
- Cross brace foam element removal installation replacement 346
- Roof bar replacement 347
- Shoulder bar replacement 349
- Checking shoulder bar alignment 350
- Articulated joint mechanism 351
- Overview 351
- Removing and installing artic ulated joint mechanism 352
- Articulated joint hand lever mechanism removal and installation 355
- Removing bowden cable for retracting stand 360
- Replace stand bowden cables 360
- Removing bowden cable for extending stand 361
- Bowden cable installation adjustment 362
- Overview 363
- Removing installing stand 363
- Stand bearings 365
- Lobe overload guard transfer element replacement 366
- Replacing tension spring s 366
- Replacing stand switch 367
- 2 6 5 4 3 368
- 9 10 12 13 368
- Overview 368
- Powertrain cradle 368
- Removing powertrain cradle mounts 368
- Coupling for swing arm bearing 370
- Tubular swing arm 371
- Installing powertrain cradle mounts 373
- Rear frame member replace ment 373
- Bracket removal and installation 374
- Luggage system bracket 374
- Support base removal and installation 375
- Upper bracket removal and installation 375
- Luggage hook replacement 376
- Luggage system lock carrier removal and installation 376
- Hinge replacement 377
- Replacing inside lock 377
- Topcase 377
- Contents 379
- Equipment 379
- Mirror bracket removal and installation 379
- Mirror removal and installation 379
- Rear storage compartment lock barrel replacement 379
- Removing ignition switch steering lock 379
- Replacing lock barrel on large small storage compartment 379
- Replacing lock barrel on luggage rail 379
- Replacing seat lock 379
- Replacing topcase lock barrel 379
- Removing ignition switch steering lock 381
- Replacing seat lock 381
- Rear storage compartment lock barrel replacement 382
- Replacing lock barrel on large small storage compartment 382
- Replacing lock barrel on luggage rail 383
- Replacing topcase lock barrel 383
- Mirror removal and installa tion 384
- Mirror bracket removal and installation 385
- Backrest removal installation replacement 387
- Contents 387
- Head restraint removal installation replacement 387
- Heated seat removal installation replacement 387
- Install seat 387
- Open the seat 387
- Remove seat 387
- Seat lock bowden cable removal and intallation 387
- Seat lock replacement 387
- Seat removal installation replacement 387
- Heated seat removal installation replacement 389
- Install seat 389
- Open the seat 389
- Remove seat 389
- Seat removal installation replacement 389
- Backrest removal installation replacement 390
- Head restraint removal installation replacement 390
- Seat lock bowden cable removal and intallation 391
- Seat lock replacement 391
- Battery 393
- Combination switch 393
- Combination switch left removal and installation 393
- Combination switch right removal and installation 393
- Contents 393
- Filler hose 393
- Filling and charging the battery 393
- General electrical equipment 393
- General view from front 393
- General view from right 393
- Installing the battery 393
- Remove the battery 393
- Removing and installing filler funnel 393
- Removing and installing filler hose 393
- Removing and installing wipe wash pump and replacing fluid reservoir 393
- Replacing filler strainer 393
- Replacing intake strainer 393
- Replacing starter relay 393
- Replacing voltage regulator 393
- Replacing wipe wash sensor 393
- Replacing wiring harness 393
- Starter relay 393
- Technical data 393
- Voltage regulator 393
- Wipe wash sensor 393
- Wiring harness 393
- Adjusting spray nozzles 394
- Contents 394
- Hose between interface at front windscreen and spray nozzles 394
- Hose between pump and interface at front windscreen 394
- Removing and installing delivery hose 394
- Removing and installing wiper arms 394
- Replacing passage in front windscreen 394
- Replacing spray nozzles 394
- Wiper motor replacement 394
- Wiring harness 397
- General view from front 398
- Replacing wiring harness 399
- Replacing wipe wash sensor 400
- Wipe wash sensor 400
- Combination switch 401
- Combination switch left removal and installation 401
- Combination switch right removal and installation 402
- Battery 403
- Remove the battery 403
- Filling and charging the battery 404
- Installing the battery 404
- Replacing starter relay 405
- Replacing voltage regulator 405
- Starter relay 405
- Voltage regulator 405
- Removing and installing wipe wash pump and replacing fluid reservoir 406
- Removing and installing filler funnel 407
- Replacing filler strainer 407
- Replacing intake strainer 407
- Filler hose 408
- Removing and installing filler hose 408
- Hose between pump and interface at front windscreen 409
- Removing and installing delivery hose 409
- Hose between interface at front windscreen and spray nozzles 410
- Adjusting spray nozzles 411
- Replacing spray nozzles 411
- Replacing passage in front windscreen 412
- Wiper motor replacement 412
- Removing and installing wiper arms 414
- Contents 415
- Fuel gauge replacement 415
- Indicator and warning lights 415
- Instrument cluster 415
- Instruments 415
- Removing and installing instrument panel 415
- Replacing bulbs 415
- Replacing wiring harness 415
- Speedometer replacement 415
- Technical data 415
- Wiring colours 415
- Removing and installing instrument panel 420
- Replacing wiring harness 420
- Fuel gauge replacement 421
- Speedometer replacement 421
- 1 5 6 7 11 422
- Indicator and warning lights 422
- Replacing bulbs 422
- Checking headlight beam angle 423
- Contents 423
- Headlight 423
- Lights 423
- Map light 423
- Map light bulb replacement 423
- Rear lights 423
- Removing and installing headlight 423
- Replacing bulb for brake light rear light 423
- Replacing front left right turn signal 423
- Replacing front left right turn signal bulb 423
- Replacing headlight bezel 423
- Replacing high beam low beam bulb 423
- Replacing intermediate frame 423
- Replacing left right rear turn signal 423
- Replacing parking light bulb 423
- Replacing rear left right turn signal bulb 423
- Replacing taillamp cluster 423
- Technical data 423
- Turn signal 423
- Headlight 427
- Removing and installing head light 427
- Replacing intermediate frame 427
- Replacing headlight bezel 428
- Replacing high beam low beam bulb 428
- Checking headlight beam angle 429
- Replacing parking light bulb 429
- Replacing front left right turn signal 430
- Turn signal 430
- Replacing front left right turn signal bulb 431
- Replacing left right rear turn signal 431
- Rear lights 432
- Replacing rear left right turn signal bulb 432
- Replacing taillamp cluster 432
- Replacing bulb for brake light rear light 433
- Map light 434
- Map light bulb replacement 434
- Activating and checking operation of alarm system 435
- Alarm system dwa 435
- Amplifier replacement 435
- Audio module replacement 435
- Contents 435
- Control unit replacement 435
- Fun audio system 435
- Indicator led replacement 435
- Motion sensor replacement 435
- Optional extras 435
- Programming the alarm system 435
- Receiver replacement 435
- Replacing alarm system bracket 435
- Replacing left right speaker brackets 435
- Service and maintenance notice 435
- Speaker removal installation replacement 435
- Volume control replacement 435
- Activating and checking operation of alarm system 437
- Alarm system dwa 437
- Service and maintenance notice 437
- Programming the alarm system 439
- Control unit replacement 441
- Indicator led replacement 441
- Receiver replacement 442
- Motion sensor replacement 443
- Replacing alarm system bracket 444
- Fun audio system 445
- Volume control replacement 445
- Amplifier replacement 446
- Speaker removal installation replace ment 446
- Replacing left right speaker brackets 447
- Audio module replacement 448
- Checking operation of central belt release mechanism 449
- Contents 449
- Inertia reel replacement 449
- Removing and installing central belt release mechanism 449
- Replacing 2 point seat belt 449
- Replacing 3 point seat belt 449
- Replacing bowden cable with belt buckles on left right 449
- Replacing guide for seat belt at shoulder bar 449
- Replacing indicator switches for seat belt 449
- Seat belts 449
- Removing and installing cen tral belt release mechanism 451
- Seat belts 451
- Checking operation of central belt release mechanism 452
- Inertia reel replacement 452
- Replacing bowden cable with belt buckles on left right 453
- Replacing indicator switches for seat belt 453
- Replacing 3 point seat belt 454
- Replacing 2 point seat belt 456
- Replacing guide for seat belt at shoulder bar 457
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