BMW R 1200 CL Service Manual
  1. Manuals
  2. Brands
  3. BMW Manuals
  4. Motorcycle
  5. R 1200 CL
  6. Service manual

BMW R 1200 CL Service Manual

R 1200 cl bmw
Hide thumbs Also See for R 1200 CL:
Table of Contents

Advertisement

Quick Links

See also: Rider's Manual , User Manual
R 1200 CL
• Technical Features in Detail
• Uncrating & Set up
• Pre Delivery Inspection
• Inspection Procedures (600 Mile)
• Special Tools
• Wiring Diagrams
BMW Motorcycles
Motorcycle Training
J:\BULLETIN\SERVICE\MCTRAINI\Manuals\R1200CL-PDI.qxd
Technical
Training
Motorcycles
09/02

Advertisement

Table of Contents
loading

Related Manuals for BMW R 1200 CL

Summary of Contents for BMW R 1200 CL

  • Page 1 R 1200 CL Technical Training • Technical Features in Detail • Uncrating & Set up • Pre Delivery Inspection Motorcycles • Inspection Procedures (600 Mile) • Special Tools • Wiring Diagrams BMW Motorcycles Motorcycle Training 09/02 J:\BULLETIN\SERVICE\MCTRAINI\Manuals\R1200CL-PDI.qxd...
  • Page 2 Technical Training conducted by BMW Motorcycles. The technician must always refer to and adhere to the following official BMW Motorrad and BMW North America, Inc service publications. • Training Materials •...

  • Page 3: Table Of Contents

    Alarm System ........113 Electrical Component Location Charts ....115 Alarm System Components and Programming Information. . 121 R 1200 CL Introduction...

  • Page 4: Introduction

    MTAS (Motorcycle Training Administration individual motorcyclist. System), http://www.bmwmc.net. This introduction brochure describes the We hope you enjoy reading this brochure. technology that lies beneath the skin of the new BMW R 1200 CL in detail as well as Technical Features in Detail...
  • Page 5 Introduction Overview. Assembled at the Berlin plant Equipment Levels. There are two ver- with its sister models, the R 1200 CL is yet sions; the base R 1200 CL and the higher another milestone for BMW Motorcycles. It trim level R 1200 CLC (custom).

  • Page 6: Engine

    Cruiser is attained. The engine output of the valves is fitted in the R 1200 CL unchanged. R 1200 CL is 45 KW (61 bhp) at 5000 RPM, the maximum torque 98 Nm (71 ft/lb) at The engine cooling system is handled by 3000 RPM.
  • Page 7 R 1200 CL Engine The two piece light alloy crankcase is man- ufactured using a pressure die-casting method.The oil pan, which holds 3.75 litres, is integrated into the engine case halves. As with all R Series bikes, the engine and gearbox is a combined load bearing ele- ment of the chassis.
  • Page 8 This has 4 chambers and is based on the reflection and absorption prin- ciple. In the exhaust silencer of the R 1200 CL, two catalytic converters are used. The small diameter and a flat design, offers a higher sectional flow.

  • Page 9: Clutch

    Centrifugal mass is of advantage for Cruiser engine speeds. This is achieved by a solid clutch case cover with the R 1200 CL. The weight of the clutch disc on the other hand, with a diameter of only 165 mm, has been reduced in order to attain a fast stand- still of the gear drive shaft.

  • Page 10: Gearbox

    R 1200 CL Gearbox The R 1200 CL is equipped with a new six The first five gears are closely graduated speed Getrag gearbox exhibiting the gear- enabling typical Cruiser riding. The sixth box codes: gear is geared considerably longer and is therefore designed as an overdrive provid- xxxxxJAE (BMW 7 673 702;...

  • Page 11: Gear Box

    R 1200 CL Gear Box The engaging and disengaging gears are The aluminum shifter drum is fixed in the located on the auxiliary shaft and the driven exact gear positions by a cam plate. The shaft. All driven gears are installed on low- die-cast aluminum shifter forks are actuat- friction needle bearings.

  • Page 12: Digital Motor Electronics (Ma 2.4)

    R 1200 CL. as on the R 1200 C Classic. This system provides a consistent idle speed of 900 RPM at normal operating The MA 2.4 control module monitors engine...
  • Page 13 R 1200 CL Digital Motor Electronics MA 2.4 The air volume drawn in is calculated (Alpha- The fuel pump – together with a fuel pres- n-control) via the angle of the throttle valve sure regulator – ensure that adequate fuel volume is available with constant pressure (Alpha) and the engine speed.
  • Page 14 R 1200 CL Digital Motor Electronics MA 2.4 The output signals for ignition and injection The fuel injectors are small and light weight. are amplified in the control module by inte- They inject fuel once per crankshaft revolu- grated output transistors. The transistors tion in parallel.
  • Page 15 R 1200 CL Digital Motor Electronics MA 2.4 The Motronic is equipped with a fuel cut-off. MA 2.4 communicates with BMW diagnos- If throttle valves are closed, an engine tem- tic equipment (MoDiTeC / GT 1) via the 10 perature is more than 70° C or an engine...

  • Page 16: Chassis And Wheels

    The chassis geometry was re-considered The telelever control arm pivots at the for the R 1200 CL due to the wider tires and engine mounting location on a continuous the different character required for a Luxury hollow shaft, which is held in maintenance- Cruiser.
  • Page 17 R 1200 CL Chassis and Wheels To prevent rocking movements in the steering system, the fork tubes are mounted to the newly designed upper fork bridge by tilt decoupled barrel joints. The fork tubes are mounted 225 mm apart from each other and connected by a new chrome plated, forged aluminum, lower fork brace.
  • Page 18 By itself, the 30mm longer R 1200 CL Telelever changes the rake angle to 56 and increases the wheelbase by the same distance.
  • Page 19 R 1200 CL Chassis and Wheels The Monolever swing arm is fixed very rigid- ly – in central cast steel parts – in backlash free taper roller bearings, thereby resulting in a short, rigid connection between the bear- ing of the rear wheel swing arm and the lon- gitudinal control arm.
  • Page 20 They are attached to the engine in the area of the longitudinal control arm bearing, the oil pan and on the considerably reinforced light metal-gearbox case. Tail Frame Section Front Wheel R 1200 CL Introduction...
  • Page 21 R 1200 CL Chassis and Wheels The new die-cast aluminum wheels with their five double spokes radiate dynamic performance and are visually supported by the powerful large tires. The rear wheel measures 4.0 x 15 with tire measuring 170/80 VR 15 for good traction, high mileage and ride comfort.
  • Page 22 R 1200 CL Brake Components and Integral ABS The brake system has been designed to The sintered metal brake pads have a brake meet the demands of a touring Cruiser. The pad surface of 86 cm .The rear wheel brake...
  • Page 23 R 1200 CL Brake Components and Integral ABS New! Brake Pad Wear Indicator When the tab of the indicator touches the pad on the other side, replace the pads. Technical Features in Detail...
  • Page 24 The BMW fully integral ABS enables the The fully integral pressure modulator of the braking efficiency to be distributed via elec- R 1200 CL is installed beneath the tank.The tronic control ensuring optimal braking brake fluid reservoirs for the front and rear power is always available on each wheel.
  • Page 25 R 1200 CL Brake Components and Integral ABS The new light weight speed sensor trigger The other lines run as follows: rings in combination with the active wheel • The orange line (actuating pressure) and speed sensors recognize wheel locking...

  • Page 26: Bodywork

    R 1200 CL Bodywork The front fairing integrated headlights These combined features result in a casual, give this motorcycle a very distinctive pleasant seating position, the anatomy of visual appeal. the knee angle being particularly distin- guished in the area of the air filter cover. The...
  • Page 27 R 1200 CL Bodywork There are two windshield versions; low and The advantage is not only an enhanced field high.The US market will receive the low ver- of vision in wet and dusty conditions. But at sion as standard equipment. The high ver- high speeds in particular, the ingenious sion can be purchased as an accessory.
  • Page 28 The side trim panels do The luggage system is integrated into the not have to be removed if the fuel tank is overall appearance of the R 1200 CL. The removed. top case with a volume of 45 litres provid- ing plenty of space for luggage.
  • Page 29 R 1200 CL Bodywork Technical Features in Detail...

  • Page 30: Headlights

    The beam distance can be adjusted to grated in a new arrangement never before compensate for two up riding with the used on a BMW Motorcycle. The head- spring-loaded lever located on left side of lamps are mounted to an adjustable sup- fairing rear surface.
  • Page 31 The adjustment screw found in the center of the load adjustment lever is used to estab- lish the base headlight position of the total headlamp assembly. This screw simultane- ously adjusts the vertical position of all four headlights. Base setting adjustment screw R 1200 CL Introduction...

  • Page 32: Cockpit And Instruments

    R 1200 CL Cockpit and Instruments The central component in the cockpit is the The warning lamps and signal indicators in instrument cluster with its three round the three centrally located rows are LEDs. gauges and the centrally located ignition lock.

  • Page 33: Electrical Components

    This is a typical with a processed speed signal from the safety feature of BMW. If a gear change is Integral ABS control module.The turn signal made when the side prop is folded out, then indicator relay is also fed with the speed the Motronic relay is switched off.

  • Page 34: Cruise Control

    R 1200 CL Cruise Control With the introduction of the R 1200 CL, This is done in intervals of approx. 1.6 km/h cruise control is equipped for the first by tipping the pushbutton. time on a BMW boxer. It is ideally suited •...
  • Page 35 R 1200 CL 1. With the ignition in the OFF position 6. Pull clutch lever in fully. SET Indicator in switch the cruise control switch to ON. cluster goes ON. Release, goes OFF . Press and hold the cruise control button 7 .
  • Page 36 R 1200 CL Cruise Control The R 1200 CL uses a new cable control Opener cable Closer cable box to converge the operation of the throt- tle from either the opener/closer cables of the throttle grip or the control cable from the cruise control actuator.
  • Page 37 R 1200 CL Cruise Control Technical Features in Detail...
  • Page 38 The R 1200 CLC is equipped with the Stereo Radio with Single Player CD as standard The sound system mounted on the handle- equipment. The Base R 1200 CL is prewired to accept the equipment as an accessory. bar clamp in the rider’s field of vision can be switched on and off in the central control panel with a digital display.
  • Page 39 BC VOICE system on MTAS. A new easily detachable dielectric rod antenna and base union are being intro- duced on the R 1200 CL. This new style union offers simplified removal and reinstal- lation when necessary for cover use.

  • Page 40: Technical Data

    R 1200 CL Technical Data Engine: Air/oil-cooled 2-cylinder 4-stroke boxer engine with four rocker arm operated valves, each with overhead camshaft and wet lubrication with two oil coolers Performance 45 kW (61 hp) @ 5000 rpm Max. torque 98 Nm (71 ft/lb) @ 3000 rpm Bore 101 mm (3.98”)
  • Page 41 R 1200 CL Technical Data Clutch: Hydraulically operated single-disc dry clutch with transmission disc spring and asbestos-free friction lining Clutch disc diameter 165 mm (6.5”) Master cylinder piston diameter 13 mm (0.5”) Slave cylinder piston diameter 24 mm (0.94”) Gearbox:...
  • Page 42 R 1200 CL Technical Data Front wheel suspension: Telelever with central strut and tilt decou- pling of the upper fork brace Full spring travel on the wheel 144 mm (5.67”) Stanchion diameter 35 mm (1.38”) Steering lock angle 35 ° right / left...
  • Page 43 R 1200 CL Technical Data Dimensions: Overall length 2,415 mm (95.0” - or - 7 .92’) Width at the rear view mirrors 1,075 mm (42.3”) Height at the top edge of the windshield 1,435 mm (56.4”) Wheelbase in normal position 1,641 mm (64.6”)
  • Page 44 Maintain your familiarity of motorcycle delivery receipt, inspection and claims processing by reviewing the following official BMW Motorcycle documents: • Motorcycle Transportation Damage Policies and Procedures. This document is available on MTAS (Service>Warranty Information).
  • Page 45 R 1200 CL PDI Procedures - Uncrating R 1200 CL Introduction...
  • Page 46 • Do this on both sides of the crate (total of 8 cuts). Remove top plastic bag Carefully lever out top supports Cut crate in 8 locations as shown (both sides) R 1200 CL Introduction...
  • Page 47 As you raise motorcycle, loosen rear shipping straps. • Cut crate base just forward of rear wheel on both sides as shown. Slide crate forward and out from under bike. Lifting Front Axle, removing pallet and supporting R 1200 CL Introduction...
  • Page 48 • Sit on bike, apply front brake to hold - Caliper Bolts = 30 Nm (22 ft/lbs) front wheel and repetitively bounce the front end to compress the front forks. As a final step, torque the remaining right side pinch bolt to spec. R 1200 CL Introduction...
  • Page 49 R 1200 CL PDI Procedures - Set Up Caution: The R 1200 CL is equipped with Integral ABS and is in residual brak- ing mode until the battery has been installed and the ignition switched on. Extra braking effort at the lever or pedal is required to stop the motorcycle when in residual braking mode.
  • Page 50 • Use shipping screws to install case to four mounting base threaded bores (1). The case mounts identi- cally to K 1200 LT model. • Reinstall covering and reattach top case stop strap and knurled screw anchor. Install Top Case R 1200 CL Introduction...
  • Page 51 R 1200 CL PDI Procedures - Set Up • Make sure the tool kit is complete. Note the new unique R 1200 CL tools included in the kit. • Tire inflation shrader valve tool • Ignition Coil removal tool • 90...
  • Page 52 ( ( H H a a v v e e a a s s s s i i s s t t a a n n c c e e m m o o v v i i n n g g a a n n I I n n t t e e g g r r a a l l A A B B S S e e q q u u i i p p p p e e d d m m o o t t o o r r c c y y c c l l e e p p r r i i o o r r t t o o b b a a t t t t e e r r y y c c o o n n n n e e c c t t i i o o n n ) ) - Adjust Handlebars to prevent damage of fuel filler door (R 1200 CL)
  • Page 53 Lift bike with auxiliary stand • Remove the riders seat (two nuts and washers under seat on left and right side). Remove Front Seat • Remove Left Right Side chrome intake pipe covers. Remove Left and Right Intake Covers R 1200 CL Introduction...
  • Page 54 If the O’ring needs replacement order only the O’ring which is available separately. O’ring P/N = 13 31 7 659 110 Remove Left and Right Intake Covers R 1200 CL Introduction...
  • Page 55 • Connect the red positive lead first, then the black negative lead last. • Remember to reconnect the vent. Replace the retaining tray. • Apply acid-proof grease to the bat- tery terminal posts. Mark the Service Date on the Battery Label R 1200 CL Introduction...
  • Page 56 • Use a shoplight to clearly see the fluid level. • Make sure no contaminant’s enter the brake fluid reservoir. • Top off with DOT 4 brake fluid as necessary. • Carefully reinstall caps. Do not overtighten. R 1200 CL Introduction...
  • Page 57 R 1200 CL PDI Procedures - Checking Brake Fluid Levels R 1200 CL Introduction...
  • Page 58 R 1200 CL PDI Procedures - Integral ABS Bleed Test BMW is the inventor of ABS for motorcycles and therefore places the greatest emphasis on safety and customer satisfaction. For that reason, this compre- hensive ABS bleed test using the MoDiTeC is required as part of the PDI process prior to any operation of the vehicle.
  • Page 59 Tire pressures are same for all condi- tions (solo, 2-up, & 2-up with luggage). Front: 2.5 bar (36.25 psi) Rear: 2.9 bar (42.05 psi) Record your measured value on the PDI sheet. Record measured Tire Pressures R 1200 CL Introduction...
  • Page 60 R 1200 CL PDI Procedures - Check Side Stand Function Check Side Stand Operation • Check for smooth side stand move- ment. Add BMW Lube if necessary (arrow). • Check side stand safety function. With transmission in gear and igni-...
  • Page 61 • If necessary, use the adjusting screws (1) and (2) to align the individual low beams to the target areas on the horizontal lines and crosses on the wall. R 1200 CL Introduction...
  • Page 62 • Insert PDI Check List along with the Integral ABS Bleed Test Trace Documentation (if applicable) into the vehicle history file. Final Cleaning: • Thoroughly wash motorcycle • Thoroughly wash tires of tire mold release agent to ensure maximum safety. Final Cleaning R 1200 CL Introduction...
  • Page 63 600 mile Inspection. • Convey product information about BMW Rider Apparel and Accessories to further the excitement of experiencing and enjoying the complete BMW product line.
  • Page 64 R 1200 CL Retail Delivery Check List Sample, Page 1 R 1200 CL Introduction...
  • Page 65 R 1200 CL Retail Delivery Check List Sample, Page 2 R 1200 CL Introduction...

  • Page 66: Mile Inspection Procedures

    In this Repair Manual, the individual maintenance inter- Maintenance tasks consist of the first Inspection (after vals the first 1 ,000 km/600 miles), the BMW Service, BMW are shown by the following codes: Inspection and BMW Annual Service. — Inspection at 1 ,000 km (600 miles)......I —...
  • Page 67 R 1200 CL US Market Service Lubricants, Sealants and Thread Lockers R 1200 CL Introduction...
  • Page 68 (or every 2 years at the latest) R 1200 C, R 1100 S Check/adjust throttle cable play; any sticking, abrasion, tightness; replace* Page 1 of 2 * invoiced as a separate item Continue on page 2 R 1200 CL Introduction...
  • Page 69 • Instruments and locks (including optional accessories: radio,alarm,cruise control,etc.) • Test ride, visual quality check • Stamp Service & technical booklet * invoiced as a separate item Page 2 of 2 Maintenance Complete, Sign and Record Mileage Below Technician Signature Date Mileage Out 9/02 R 1200 CL Introduction...
  • Page 70 R 1200 CL BMW Inspection I Procedures (600 Miles) Check Vehicle History for outstand- Check ABS sensors and pulse wheels for correct gap/contamina- ing Recalls using BMW DCSnet tion BMW inspections/services I, II, III, IV BMW inspections/services I, II, III, IV •...
  • Page 71 R 1200 CL BMW Inspection I Procedures (600 Miles) Re-torque cylinder head Inspection I (600 Mi. only) • Remove ignition coils using new special tool 12 3 561 • Remove cylinder head covers. C C a a u u t t i i o o n n : catch draining oil.
  • Page 72 R 1200 CL BMW Inspection I Procedures (600 Miles) Checking / adjusting valve clear- ance BMW inspections/services I, II, III, IV • Check valve clearances with two feeler gauges simultaneously and engine temperature below 95 • Adjust clearance if necessary...
  • Page 73 R 1200 CL BMW Inspection I Procedures (600 Miles) Changing Engine Oil & Filter BMW inspections/services I, II, III, IV Note: Drain oil with engine at operat- ing temperature. • Remove fill plug. • Unscrew oil drain plug & drain oil.
  • Page 74 R 1200 CL BMW Inspection I Procedures (600 Miles) Changing rear drive oil BMW inspections/services I, III, IV • Unscrew oil filler plug and oil drain plug/drain oil. • Screw in oil drain plug with new sealing ring. • Fill with transmission oil.
  • Page 75 R 1200 CL BMW Inspection I Procedures (600 Miles) Check throttle/cruise control cables play - adjust only if necessary. BMW inspections/services I, II, III, IV - Only with cold engine (< 35 C / 95 • Switch Ignition on to allow the idle control motor to position the throttle plates for cold engine starting.
  • Page 76 R 1200 CL BMW Inspection I Procedures (600 Miles) Torque Rear Wheel bolts BMW inspections/services I • Tighten the rear wheel studs in a crosswise pattern. Tightening torque: Rear wheel studs; 105 Nm (77 ft. lb.) Check the rear drive, wheel, and...
  • Page 77 R 1200 CL BMW Inspection I Procedures (600 Miles) Check throttle synchronization val- ues with MoDiTeC BMW inspections/services I, II, III, IV Note: The R 1200 CL has a common throttle linkage system and an Idle Control management feature Motronic.
  • Page 78 R 1200 CL BMW Inspection I Procedures (600 Miles) F F i i n n a a l l I I n n s s p p e e c c t t i i o o n n w w i i t t h h r r o o a a d d s s a a f f e e t t y y...
  • Page 79 Tvyrpr…Ãurh‡Ã†uvryq Srh…ÐurryÃq…v‰rȁv‡Ãq…hvÃƒyˆt !" I€ Srh…ÐurryÃq…v‰rȁv‡Ãsvyyr…Ãyˆt !" I€ AˆryÇhxÇ‚Ã…rh…Ãs…h€r I€ 8’yvqr…ÃurhqÁˆ‡† G‚‚†rÃÃ! I€Ã‚vyrq  ' ƒÃhqqv‡v‚hyÃhtyrÂsÃ…‚‡h‡v‚ 8’yvqr…ÃurhqÆp…rÃH  I€ G‚pxˆ‡Éhy‰rÃhqwˆ†‡vtÆp…r I€ 8’yvqr…ÃurhqÃp‚‰r… I€ Tƒh…xÃyˆt† I€ 7…hxrÃphyvƒr…Ãs…‚‡Ç‚Æyvqr…Ljir " I€ 7…hxrÃphyvƒr…Ã…rh…Ç‚Ã…rh…ÐurryÃq…v‰r I€ Ah†‡rr…ÂsĈvpx…ryrh†rÃh‘yrÃs…‚‡Ãurry " I€ 8yh€ƒÃ†p…r†Ã‚sĈvpx…ryrh†rÃh‘yrÃs…‚‡Ãurry I€ Srh…ÐurryÇ‚Ã…rh…ÐurryÃq…v‰rȁv‡ I€ R 1200 CL Introduction...

  • Page 80: New Special Tools

    They are in the initial tool package and have been shipped to every US market BMW Motorcycles Retailer. Also included in the R 1200 CL ini- tial tool package are additional tools for F 650 CS and the latest SD ROM (9/02).
  • Page 81 Part of Automatic Tool Shipment Ignition Coil Extractor Adapter Cable 90 88 6 122 501 Used to interface ignition coil primary circuit with MoDiTeC for diagnosis Part of Automatic Tool Shipment Check primary ignition wave form with MoDiTeC R 1200 CL Introduction...

  • Page 82: New Special Tools

    Removal and install of Drain Plug (2) Caliper Spreader 90 88 6 341 591 Resets caliper pistons for bleeding and pad replacement on rear caliper Part of Automatic Tool Shipment R 1200 CL specific rear caliper spreader R 1200 CL Introduction...
  • Page 83 Check secondary ignition wave form with MoDiTeC Pulley Holder 90 88 6 127 511 Used to hold belt pulley for nut removal and torquing when installing new nut. Part of Automatic Tool Shipment Checks pulley in place when torquing R 1200 CL Introduction...
  • Page 84 R 1200 CL F 650 CS Introduction...
  • Page 105 • Turn off the ignition. • Wait for the control LED to flash, the system is now armed. • DisArm the alarm system by pressing button A. Programming procedure is now completed. R 1200 CL Introduction...
  • Page 106 NOTE: If the beeps are not heard, you must repeat steps 2 - 5 ensur- ing the key is switched ON after the last flash of the coded number switches OFF . Example: Code input for 11559 R 1200 CL Introduction...

  • Page 107: Alarm System

    • Once released, the RF Remote LED will light up steadily. • Press either button A or B. • A beep will indicate that the encoding of the remote control has been suc- cessful. • Repeat the procedure for all other remote controls. R 1200 CL Introduction...

Table of Contents