BMW R 1200 CL Wartungshandbuch

MotorcyclesTechnicalTrainingBMW MotorcyclesMotorcycle TrainingJ:\BULLETIN\SERVICE\MCTRAINI\Manuals\R1200CL-PDI.qxdR 1200 CL• Technical Features in Det

8The R 1200 CL is equipped with a new sixspeed Getrag gearbox exhibiting the gear-box codes:xxxxxJAE (BMW 7 673 702; GETRAG424.0.0003.04) = 6 speed, s

R 1200 CL113 /114R 1200 CL IntroductionAlarm System (DWA)

R 1200 CL115 /116R 1200 CL IntroductionFuse Designations and Electrical Components View 1

R 1200 CL117 /118R 1200 CL IntroductionElectrical Components View 2

R 1200 CL119 /12 0R 1200 CL IntroductionElectrical Components View 3

R 1200 CL121/122R 1200 CL IntroductionAlarm System Components and Programming informationOverviewThe alarm system is programmed for various functionc

123R 1200 CLAlarm System Programming InformationProgramming ProcedureThe alarm system is designed for 12 programmable functions. However, only 5functi

124R 1200 CL IntroductionR 1200 CLAlarm System Programming InformationNote:To encode RF Remote Controlsyou will need the 5 digit “personal pincode” fo

Encoding the remote controlsNote: All RF remote controls must beencoded at the same time for them to befunctional• Press and hold buttons A and B on t

9The engaging and disengaging gears arelocated on the auxiliary shaft and the drivenshaft. All driven gears are installed on low-friction needle beari

10The R 1200 CL is equipped with DigitalMotor Electronics (Motronic) MA 2.4engine management system. In contrastto the Motronic MA 2.4 for the R 1150m

11The fuel pump – together with a fuel pres-sure regulator – ensure that adequate fuelvolume is available with constant pressureto the fuel injectors.

12The output signals for ignition and injectionare amplified in the control module by inte-grated output transistors. The transistorsswitching on and

13The Motronic is equipped with a fuel cut-off.If throttle valves are closed, an engine tem-perature is more than 70° C or an enginespeed exceeds 1800

14The R 1200 CL has a wheelbase of1641mm, which is actually 9mm shorterthan the Classic. The rake angle and trailmeasurement have also been changed.Th

15R 1200 CLChassis and WheelsTechnical Features in DetailTo prevent rocking movements in the steering system, the fork tubes are mounted to thenewly d

16R 1200 CLChassis and WheelsTechnical Features in DetailThe travel of the front wheel is damped by acentral suspension strut with twin-sleevedamper p

17R 1200 CLChassis and WheelsTechnical Features in DetailThe Monolever swing arm is fixed very rigid-ly – in central cast steel parts – in backlashfre

BMW of North America, LLC BMW MotorcyclesZU-X-S-51R 1200 CLDisclaimerR 1200 CL IntroductionThis training reference book is not intended to be a comple

18R 1200 CLChassis and WheelsTail Frame SectionFront WheelR 1200 CL IntroductionThe rear frame section is welded togetherby a combination of tubular,

Front & Rear Wheels19The new die-cast aluminum wheels withtheir five double spokes radiate dynamicperformance and are visually supported bythe pow

20R 1200 CLBrake Components and Integral ABSTechnical Features in DetailThe brake system has been designed tomeet the demands of a touring Cruiser. Th

21R 1200 CLBrake Components and Integral ABSTechnical Features in DetailNew!Brake Pad Wear IndicatorWhen the tab of the indicatortouches the pad on th

22The BMW fully integral ABS enables thebraking efficiency to be distributed via elec-tronic control ensuring optimal brakingpower is always availabl

23R 1200 CLBrake Components and Integral ABSTechnical Features in DetailThe new light weight speed sensor triggerrings in combination with the active

24The front fairing integrated headlightsgive this motorcycle a very distinctivevisual appeal.The fairing integrated mirrors (which alsohouse the dir

25There are two windshield versions; low andhigh.The US market will receive the low ver-sion as standard equipment. The high ver-sion can be purchased

26R 1200 CLBodyworkTechnical Features in DetailThe mirror housings are designed as aero-dynamic hand protectors. They are ventilat-ed at the rear in o

27R 1200 CLBodyworkTechnical Features in Detail

1R 1200 CLTable of ContentsR 1200 CL IntroductionSubject PageTechnical Features in DetailIntroduction . . . . . . . . . . . . . . . . . . . . . . . .

28The four round headlights have been inte-grated in a new arrangement never beforeused on a BMW Motorcycle. The head-lamps are mounted to an adjustab

R 1200 CLHeadlightsBase setting adjustment screwR 1200 CL Introduction29Lever Positions:Horizontal: normal position (shown); Alwaysadjust base setting

30R 1200 CLTechnical Features in DetailThe central component in the cockpit is theinstrument cluster with its three roundgauges and the centrally loca

31R 1200 CLTechnical Features in DetailThe neatly arranged electrical system islocated under the fuel tank and is thebasis for operating the electrica

32R 1200 CLTechnical Features in DetailWith the introduction of the R 1200 CL,cruise control is equipped for the firsttime on a BMW boxer. It is ideal

331. With the ignition in the OFF positionswitch the cruise control switch to ON.Press and hold the cruise control buttonin the SET position and turn

34R 1200 CLCable box location Cable Box internal viewR 1200 CL IntroductionThe R 1200 CL uses a new cable controlbox to converge the operation of the

35R 1200 CLCruise ControlTechnical Features in Detail

Technical Features in Detail36R 1200 CLThe sound system mounted on the handle-bar clamp in the rider’s field of vision can beswitched on and off in th

37R 1200 CLSound and Communication SystemTechnical Features in DetailThe right side case also includes a coolingfan system for the electronics. The fa

2R 1200 CLIntroductionTechnical Features in DetailThe new R 1200 CL luxury Cruiser:individual product personality, visualappeal featuring unique speci

38Technical Features in DetailR 1200 CLEngine:PerformanceMax. torqueBoreStrokeEffective capacityStroke/bore ratioCompression ratioFuelAngle of valve i

39Technical Features in DetailTechnical DataR 1200 CLClutch:Clutch disc diameterMaster cylinder piston diameterSlave cylinder piston diameterGearbox:P

40Technical Features in DetailTechnical DataR 1200 CLFront wheel suspension:Full spring travel on the wheelStanchion diameterSteering lock angleSpring

41R 1200 CLTechnical DataTechnical Features in DetailDimensions:Overall lengthWidth at the rear view mirrorsHeight at the top edge of the windshieldWh

R 1200 CL IntroductionR 1200 CLPDI Procedures - Uncrating Delivery and Crate InspectionWhile the motorcycle is being unloaded by the shipper,thoroughl

R 1200 CLPDI Procedures - Uncrating R 1200 CL Introduction43

Cut crate in 8 locations as shown (both sides)44R 1200 CLPDI Procedures - Uncrating Uncrating the motorcycle • With the crate on a level surface,remo

R 1200 CLPDI Procedures - Uncrating • Remove the front tire from the right side area of the crate and set it aside.• Remove both side panels from the

46R 1200 CLPDI Procedures - Set UpR 1200 CL Introduction• Clean area under motorcycle com-pletely ensuring any sharp objectsor nails are removed.• Ins

47R 1200 CLPDI Procedures - Set UpR 1200 CL Introduction• Top Illustration. Remove theInstrument panel center trim (2) byremoving securing screws

3Overview. Assembled at the Berlin plantwith its sister models, the R 1200 CL is yetanother milestone for BMW Motorcycles. Ittakes its place in the li

48R 1200 CLPDI Procedures - Set UpR 1200 CL Introduction• The handlebars are lowered toallow the motorcycle to fit into thecrate for shipping. HANDLEB

49R 1200 CLPDI Procedures - Set UpR 1200 CL IntroductionMake sure tool kit is complete• Make sure the tool kit is complete.Note the new unique R 1200

R 1200 CLPDI Checklist SampleR 1200 CL Introduction50BMW MotorcyclesPre-delivery checkR 1150 R R 1100 S R 1150 RT R 1150 GS R 1200 C R 1200

51R 1200 CLPDI Procedures - Accessing BatteryR 1200 CL Introduction• With an assistant, place motorcycleonto the auxiliary center stand.Make sure pin

R 1200 CLR 1200 CL Introduction52PDI Procedures - Accessing Battery• Remove both Left and Right sidepainted trim covers (2) by removingtwo screws (1).

PDI Procedures - Removing, Filling and Charging Battery53R 1200 CLR 1200 CL IntroductionNote: Various models will eventually befactory equipped with a

54R 1200 CLPDI Procedures - Checking Brake Fluid LevelsR 1200 CL IntroductionIntegral ABS has four separate brakecircuits. Fluid levels are checked at

55R 1200 CLPDI Procedures - Checking Brake Fluid LevelsR 1200 CL Introduction

56R 1200 CLPDI Procedures - Integral ABS Bleed TestR 1200 CL IntroductionBleed Test RequirementsPrior to performing Bleed Test, make sure the followi

57R 1200 CLPDI Procedures - Check Engine Oil LevelR 1200 CL IntroductionBattery:- Remove battery- Add battery acid- Allow battery to cool prior to ch

4The proven 1200 cc R 259 variant, withhigh-camshaft-valve control and fourvalves is fitted in the R 1200 CL unchanged.The engine cooling system is ha

58R 1200 CLPDI Procedures - Check Side Stand FunctionR 1200 CL IntroductionCheck Side Stand Operation• Check for smooth side stand move-ment. Add BMW

59R 1200 CLPDI Procedures - Check Headlight AlignmentR 1200 CL Introduction• Set the shock preload to solo mode.• Place adjustment lever to the hori-

PDI Procedures - Final Inspections and Function Checks60R 1200 CLR 1200 CL IntroductionFill Fuel Tank• Fill the fuel tank with premium unleaded gasoli

61Retail Delivery Handover ProcessR 1200 CL IntroductionR 1200 CL• The customer delivery process or“handover” is a critical step in establish-ing a s

62R 1200 CLRetail Delivery Check List Sample, Page 1R 1200 CL Introduction

63R 1200 CLRetail Delivery Check List Sample, Page 2R 1200 CL Introduction

64R 1200 CL600 Mile Inspection ProceduresR 1200 CL IntroductionMaintenance Schedule Checklist• The Maintenance Schedule Checklist is used to make sure

65R 1200 CLUS Market Service Lubricants, Sealants and Thread LockersR 1200 CL Introduction

R 1200 CL Introduction66R 1200 CLMaintenance Schedule Checklist, Page 1BMW Inspection600 milesBMW Service6,000 milesBMWAnnual ServiceBMW Inspection12,

R 1200 CLR 1200 CL Introduction67Maintenance Schedule Checklist, Page 2BMW Service6,000milesBMW Inspection600milesBMW Inspection12,000milesBMWAnnual

5The two piece light alloy crankcase is man-ufactured using a pressure die-castingmethod.The oil pan, which holds 3.75 litres,is integrated into the e

R 1200 CLR 1200 CL Introduction68Check Vehicle History for outstand-ing Recalls using BMW DCSnetBMW inspections/services I, II, III, IV• www.bmwdcsne

BMW Inspection I Procedures (600 Miles)Re-torque cylinder headInspection I (600 Mi. only) • Remove ignition coils using new special tool 12 3 561• Rem

70R 1200 CLBMW Inspection I Procedures (600 Miles)Checking / adjusting valve clear-anceBMW inspections/services I, II, III, IV• Check valve clearances

71R 1200 CLBMW Inspection I Procedures (600 Miles)Changing Engine Oil & FilterBMW inspections/services I, II, III, IVNote: Drain oil with engine a

72R 1200 CLBMW Inspection I Procedures (600 Miles)Changing rear drive oilBMW inspections/services I, III, IV• Unscrew oil filler plug and oil drainplu

73R 1200 CLBMW Inspection I Procedures (600 Miles)Check throttle/cruise control cablesplay - adjust only if necessary.BMW inspections/services I, II,

74R 1200 CLBMW Inspection I Procedures (600 Miles)Torque Rear Wheel boltsBMW inspections/services I• Tighten the rear wheel studs in acrosswise patter

75R 1200 CLBMW Inspection I Procedures (600 Miles)Check throttle synchronization val-ues with MoDiTeCBMW inspections/services I, II, III, IVNote: The

76R 1200 CLBMW Inspection I Procedures (600 Miles)FFiinnaall IInnssppeeccttiioonn wwiitthh rrooaadd ssaaffeettyyaanndd ffuunnccttiioonn cchheecc

77R 1200 CLService & Maintenance DataR 1200 CL Introduction,WHP 6SHFLILFD W LRQ 8QLWV6SHFLILFDWLRQV

6R 1200 CLEngineThe engine is designed to run on premiumgrade fuel (95 RON/92 AKI).The air fuel mix-ture is ignited by a centrally placed sparkplug.Di

Special Tool Catalog on MTASThe special tools catalog has been restructured on MTAS. The tools are nowcategorized and accessed via the “On-line Bullet

79R 1200 CLNew Special Tools - Part of Automatic Initial Tool ShipmentR 1200 CL IntroductionAuxiliary Stand 90 88 6 001 630Base: 90 88 6 001 631Jack:

80R 1200 CLNew Special ToolsR 1200 CL IntroductionAdapter Cable 90 88 6 127 050Used to interface ignition coil sec-ondary circuit with MoDiTeC.Part of

81F 650 CS Additional InformationNew Special Tools For F 650 CSR 1200 CL IntroductionAdapter Cable 90 88 6 122 511Used to interface ignition coil prim

R 1200 CLF 650 CS Introduction82

R 1200 CL83/84R 1200 CL IntroductionWiring & Terminal Designations Electrical Component Designation LegendA = Control Units (Processors)A9001 Ins

R 1200 CL85/86R 1200 CL IntroductionPower Distribution and Grounds - Part 1 of 2

R 1200 CL87/88R 1200 CL IntroductionPower Distribution and Grounds - Part 2 of 2

R 1200 CL89/90R 1200 CL IntroductionStarter and Alternator

R 1200 CL91/92R 1200 CL IntroductionMotronic M2.4 without Anti-Theft System (Part 1 of 2)

7R 1200 CLClutchCentrifugal mass is of advantage for Cruiserengine speeds. This is achieved by a solidclutch case cover with the R 1200 CL.The weight

R 1200 CL93/94R 1200 CL IntroductionMotronic M2.4 with Anti-Theft System (Part 1 of 2)

R 1200 CL95/96R 1200 CL IntroductionMotronic M2.4 with or without Anti-Theft System (Part 2 of 2)

R 1200 CL97/98R 1200 CL IntroductionAnti Lock Brakes

R 1200 CL99/100R 1200 CL IntroductionCruise Control

R 1200 CL101/102R 1200 CL IntroductionInstrumentation (Part 1 of 2)

R 1200 CL103/104R 1200 CL IntroductionInstrumentation (Part 2 of 2)

R 1200 CL105/106R 1200 CL IntroductionLights

R 1200 CL107/108R 1200 CL IntroductionHorn, Hazard Flashers & Turn Signal Lights

Radio/CD PlayerR 1200 CL109/110R 1200 CL Introduction

R 1200 CL111 / 112R 1200 CL IntroductionHeated Grips/Seat & Diagnostic Connector