R 1200 CL

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


Disclaimer 

This training reference book is not intended to be a complete and all inclusive 

source of servicing, repairing or troubleshooting the motorcycle. This is only part 

of the training information designed to ensure that uniform procedures and 

information are presented to all participants of 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 

• Repair Manuals 

• Service Bulletins 

• MoDiTeC 

Service Bulletins are issued by the BMW Motorcycle Service Department, 

regarding changes in operation, and repair or maintenance procedures. Service 

Bulletins are available on MTAS (www.bmwmc.net). From the departments menu 

button on the home page, select “On-line bulletin search”. 

Information Status, (date indicated on front cover). 

For changes/additions to the technical data, please refer to current information 

issued by the BMW NA Motorcycle Service Department. 

BMW of North America, LLC 


ZU-X-S-51 

R 1200 CL Introduction


Table of Contents 

Subject Page 

Technical Features in Detail 

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 

Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 

Digital Motor Electronics (MA 2.4) . . . . . . . . . . . . . . . . . . . . . 10 

Chassis and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 

Brakes (Integral ABS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 

Bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 

Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 

Cockpit and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 

Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 

Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 

Sound and Communication Systems. . . . . . . . . . . . . . . . . . . 36 

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 

Pre Delivery Inspection Procedures . . . . . . . . . . . . . . . . . . . . . 42 

Retail Delivery Handover Procedure . . . . . . . . . . . . . . . . . . . . . 61 

600 Mile Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . 64 

New Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 

Wiring Diagrams 

Terminal & Electrical Component Designation Legend . . . . . 83 

Power Distribution & Grounds . . . . . . . . . . . . . . . . . . . . . . . . 85 

Starter & Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 

Motronic MA 2.4 Engine Management. . . . . . . . . . . . . . . . . . 91 

Anti-lock Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 

Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 

Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 

Horn,Turn Indicators with Hazard Flashers . . . . . . . . . . . . . . 107 

Radio/CD Player . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 

Heated Grips/Seat and Diagnostic Plug . . . . . . . . . . . . . . . . 111 

Alarm System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 

Electrical Component Location Charts . . . . . . . . . . . . . . . . . . 115 

Alarm System Components and Programming Information. . 121 

R 1200 CL Introduction 

1


Introduction 

The new R 1200 CL luxury Cruiser: 

individual product personality, visual 

appeal featuring unique specifications in 

the Cruiser segment. 

The distinctive look of the new BMW 

boxer flat-twin appeals to the taste of the 

individual motorcyclist. 

This introduction brochure describes the 

technology that lies beneath the skin of the 

new BMW R 1200 CL in detail as well as 

2 

Pearl Silver Metallic 

uncrating, set up, PDI and maintenance 

information. However, allways refer to technical 

data in the relevant publications found 

the Service and Technical Training areas of 

MTAS. 

MTAS (Motorcycle Training Administration 

System), http://www.bmwmc.net. 

We hope you enjoy reading this brochure. 

Technical Features in Detail


Introduction 

Overview. Assembled at the Berlin plant 

with its sister models, the R 1200 CL is yet 

another milestone for BMW Motorcycles. It 

takes its place in the line up of previously 

introduced R 1200 C models including the 

Classic introduced in 1997, and the later 

model variants including the R 1200 C 

Montana, Euro, Stilleto and Phoenix, all of 

which have laid the foundation for an 

extremely successful series. 

The name identifies the character of this 

new R Series addition; R 1200 CL: Cruiser 

and Luxury, comfort with everyday suitability 

and a powerful appearance. 

In addition to the Pearl Silver Metallic shown 

on the previous page, color choices at time 

of introduction also include: 

Mojave Brown Metallic 

Capri Blue Metallic 


Equipment Levels. There are two versions; 

the base R 1200 CL and the higher 

trim level R 1200 CLC (custom). 

In addition to the Fully Integral ABS, other 

upgrades are provided as standard equipment 

on the base R 1200 CL including: 

• cruise control, 

• two-stage heated grips, 

• chrome package, 

• and prewiring for the factory stereo 

radio/single disc CD player. 

The R 1200 CLC is additionally equipped 

with: 

• stereo radio / single disc CD player 

with handlebar mounted control, 

• heated, comfort seat. 

Accessories. Accessories are also available 

for both versions including: 

• plug in Factory Alarm System, 

• Comfort-Squab (separate backrest) 

• Top Case Speakers 

• Floorboard footrest for passenger 

• Cup holder (like K 1200 LT) 

• BC-V.O.I.C.E. Board Communications - Voice 

Operated Intercom Communication Equipment. 

• CB Radio and antenna 

• Luggage soft bag inserts for side cases 

• Cylinder head engine protection bars 

• Side case protection bars 

Image.The distinctive fairing silhouette with 

the four headlights and innovative bodywork 

design integrated standard top and 

side case storage concept tempt you to get 

on and ride. The riding position, designed 

for good handling, provides direct contact 

with the motorcycle thanks to the wide handlebars 

and low, comfortable seat. 

A standard seat height of 745 mm (29.3”) 

has been designed intentionally low for all 

riders in order to ensure easy control over 

the motorcycle when in standing position. 

3


Engine 

The proven 1200 cc R 259 variant, with 

high-camshaft-valve control and four 

valves is fitted in the R 1200 CL unchanged. 

The engine cooling system is handled by 

twin oil-coolers integrated in the front 

frame. Oil circulation is supplied by its own 

oil pump, regulated by a thermostat.The oil 

flows through both oil coolers in succession; 

lubricating oil and cooling oil are separated. 

Engine management is controlled by the 

Motronic MA 2.4. in conjunction with the performance-determining 

components, such s 

camshafts, valve sizes, air intake design, the R 

1200 CL engine is also designed in such a 

4 

way that a torque range desired for a luxury 

Cruiser is attained. The engine output of the 

R 1200 CL is 45 KW (61 bhp) at 5000 RPM, 

the maximum torque 98 Nm (71 ft/lb) at 

3000 RPM. 

The engine’s displacement and dynamic 

specifications are: 

Displacement = 1170 cc 

Bore x Stroke = 101 mm x 73 mm 

Pistons = short skirt light alloy box piston 

Compression Ratio = 10.0:1, 

Camshaft profile = 256° 

The exhaust system is designed according 

to the bikes cruiser characteristic. 



Engine 

The two piece light alloy crankcase is manufactured 

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 element 

of the chassis. For this reason, both 

case halves were designed with a specific 

rigidity with the aid of computer calculations 

of the Finite Element Method. 

The 1-piece forged crankshaft is accommodated 

centrally in the crankcase on sliding 

bearings. It runs on two bearings, the rear 

bearing being larger and designed as a 

double collar bearing. The 125 mm long 

connecting rods are made of sintered steel 

and are cracked at the big end. 

The weight-optimized box pistons are made 

of light alloy and have machined valve 

notches on the piston crown. A pressure 

release channel above the piston ring zone 

prevents a partial vacuum from building up 

in the combustion chamber during engine 

cool down to prevent oil from being pulled 

in under vacuum when the engine is off. 

The camshafts are mounted into the cylinder 

heads by separate camshaft carriers. 

The cams are made up of a case-hardened 

shaft with pressed-on individual cams 

made of sintered material. 

The camshafts are roller chain driven at a 

2:1 ratio geared down by the auxiliary shaft, 

which is located below the crankshaft and 

also drives both duo-centric oil pumps. 

The valves all have 5 mm valve stems.They 

are actuated in pairs by clear chill cast tappets, 

short aluminum tappet push rods and 

forged valve lifters. 


Engine Components 

Crankshaft / Pistons 

Cylinder head / Valve train 

5


Engine 

The engine is designed to run on premium 

grade fuel (95 RON/92 AKI).The air fuel mixture 

is ignited by a centrally placed spark 

plug. 

Directly connected to each spark plug are 

the new direct connection ignition coils (ie: 

F 650 CS). These coils eliminate the secondary 

spark plug wire ensuring consistent 

spark voltage over the lifetime of the motorcycle. 

Due to the ignition coils, the cylinder 

head covers are new.The ignition coils each 

have a separate ground wire that connects 

to the engine cylinder head. 

The exhaust system with a hard chrome 

plated surface is produced in three sections: 

two exhaust manifolds consisting of a 

55 mm double walled tube and a flangemounted, 

1-section exhaust silencer with 

short tail pipes.This has 4 chambers and is 

based on the reflection and absorption principle. 

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. The cylindrical catalytic converter 

carriers have a diameter of 60 mm 

and a length of 74 mm. 

The heated O2 sensor is located in the 

exhaust gas stream of the two exhaust manifolds 

beyond the catalytic converters. 

During the warm-up period from 60° C 

motor oil temperature (just a few minutes 

after starting), it already ensures that the 

engine runs in accordance with the stoichiometric 

mixture (lambda=1). 

The catalytic converters are made of palladium 

and rhodium. Palladium accelerates 

the oxidation of hydrocarbons and carbon 

monoxide. Rhodium reduces nitric oxide. 

6 

New Ignition Coils 

Exhaust Components 

Twin Catalytic Converters, Single O 2 Sensor 



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 standstill 

of the gear drive shaft. 

This optimizes the engaging and disengaging 

of the 6-speed gearbox.The wear resistant 

friction lining of the clutch disc together 

with the strong casing cover additionally 

offers high temperature resistance. 


Clutch Components 

7


Gearbox 

The R 1200 CL is equipped with a new six 

speed Getrag gearbox exhibiting the gearbox 

codes: 

xxxxxJAE (BMW 7 673 702; GETRAG 

424.0.0003.04) = 6 speed, silver painted 

xxxxxJAF (BMW 7 673 703; GETRAG 

424.0.0003.05) = 6 speed, black painted 

8 

The first five gears are closely graduated 

enabling typical Cruiser riding. The sixth 

gear is geared considerably longer and is 

therefore designed as an overdrive providing 

pleasant touring with lower fuel consumption 

on interstate journeys. 

In the light alloy casing, three gear shafts 

are installed in wear-resistant clean-bearing 

deep groove ball bearings. 



Gear Box 

The engaging and disengaging gears are 

located on the auxiliary shaft and the driven 

shaft. All driven gears are installed on lowfriction 

needle bearings. 

The new heal/toe shifter transfers the riders 

shift action to the gearbox through ball and 

pin pivots to the input shaft. The heal/toe 

shifter is made of chrome plated forged aluminum. 


The aluminum shifter drum is fixed in the 

exact gear positions by a cam plate. The 

die-cast aluminum shifter forks are actuated 

by the shifting gates of the camshaft 

controllers via anti-friction steel bushes.The 

shifter forks glide smoothly on hollow bored 

steel shafts and engage the gears exactly. 

The gear pair of the primary drive has a quietly 

running, wear-resistant spiral gearing. 

All other gears are provided with a spur 

toothing and are constructed tightly interlocked.This 

provides smoother meshing for 

particularly quiet running. 

The hollow-bored drive shaft bears a compact, 

two phase starting damper. The rotational 

oscillations occurring during the idle 

speed of the engine are absorbed by a prestressed 

washer. A heavy-duty coil spring 

works in the main damper, which is responsible 

for reducing the noise occurring during 

the changing of gear and load. 

9


Digital Motor Electronics MA 2.4 

The R 1200 CL is equipped with Digital 

Motor Electronics (Motronic) MA 2.4 

engine management system. In contrast 

to the Motronic MA 2.4 for the R 1150 

models, an electronically regulated cold 

start control with idle speed control is 

used for the R 1200 CL. as on the R 1200 

C Classic. 

The MA 2.4 control module monitors engine 

operating parameters via input signals from 

sensors and switches. 

10 

These input values are evaluated by the 

control module and used for calculating the 

injection on time and frequency, optimum 

ignition timing angle and idle speed control 

based on programmed operating data 

maps. 

This system provides a consistent idle 

speed of 900 RPM at normal operating 

temperature as well as automatic increased 

speeds for cold engine startup which gradually 

changes as the engine warms up. 




The fuel pump – together with a fuel pressure 

regulator – ensure that adequate fuel 

volume is available with constant pressure 

to the fuel injectors. The fuel pump is 

switched on by the fuel pump relay which is 

controlled by the MA 2.4 control module.The 

fuel system pressure in the distributor is 

constant 3 bar. 

The Motronic control module receives the 

most important input signals from the hall 

sensors (crankshaft rotational speed and 

top dead center piston position) and from 

the throttle position sensor (angular position 

of the throttle valves). 


The air volume drawn in is calculated (Alphan-control) 

via the angle of the throttle valve 

(Alpha) and the engine speed. The fine-tuning 

takes place via an engine temperature 

sensor, and the air temperature sensor and 

the integrated barometric pressure sensor. 

The oxygen sensor monitors the amount of 

remaining oxygen content in the exhaust 

gas. This allows the control module to 

manipulate the fuel injector on time (Ti) to 

maintain the optimum air fuel mixture. All 

information is compared with the programmed 

characteristics in the control unit. 

11



The output signals for ignition and injection 

are amplified in the control module by integrated 

output transistors. The transistors 

switching on and off activates the fuel injector 

solenoid valves and the primary ignition 

coil windings. 

The cold-start control works with an actuator 

with a worm gear pair that directly actuates 

the two throttle valves in the intake 

manifold. The control signal is calculated 

from the signals of the engine temperature 

and from the speed of the crankshaft with 

response. 

The ideal positions of the throttle valves are 

set for all operational states by means of an 

adaptive control adjustment maintained by 

the control module. 

12 

The fuel injectors are small and light weight. 

They inject fuel once per crankshaft revolution 

in parallel. 

To achieve optimal running of the engine 

during the start-up and warming phase, fuel 

enrichment is provided by activating the 

injectors twice as often during starting 

phase, then switching over to the once per 

crankshaft revolution injection scheme with 

a longer ontime to proved enrichment. As 

the engine warms the on time is reduced. 

When the maximum engine speed of 7000 

rpm has been reached, the injection time is 

interrupted in order to limit the speed. 




The Motronic is equipped with a fuel cut-off. 

If throttle valves are closed, an engine temperature 

is more than 70° C or an engine 

speed exceeds 1800 rpm, then the activation 

of the fuel injectors is interrupted.When 

the engine speed reduces to 1400 RPM or 

below, the injectors are reactivated. 

The failure of a sensor signal (with the 

exception of Hall sensors) is detected by 

the control module through electrical monitoring 

and plausibility. When this happens, 

a fault is set for the failed input signal and 

alternate default value is used allowing the 

motorcycle to continue running. 


MA 2.4 communicates with BMW diagnostic 

equipment (MoDiTeC / GT 1) via the 10 

pin diagnostic plug located under the left 

side chrome cover. 

13


Chassis and Wheels 

The R 1200 CL has a wheelbase of 

1641mm, which is actually 9mm shorter 

than the Classic. The rake angle and trail 

measurement have also been changed. 

The chassis geometry was re-considered 

for the R 1200 CL due to the wider tires and 

the different character required for a Luxury 

Cruiser. The angles were a calculated decision, 

resulting in both appearance and 

functionality. These changes necessitated 

the following new components specifically 

made for this bike; 

• 30 mm longer telelever control arm, 

• wider chrome plated upper fork bridge, 

• wider lower fork brace with repositioned 

ball joint mounting socket 

14 

Additionally, the attachment points for the 

brake calipers had to be modified to comply 

with the EVO caliper dimensions requiring 

new stanchion tubes for the front forks. 

The telelever control arm pivots at the 

engine mounting location on a continuous 

hollow shaft, which is held in maintenancefree 

ball bearings. 

The front frame section is made of die cast 

aluminum, which is the best method for 

moulding shapes and surfaces. It’s firmly 

attached to the crankcase at four points. 

The cast frame provides a mounting point 

for the new chrome plated, forged aluminum, 

upper fork bridge. The fork bridge 

steering bearings are reinforced doublerow 

flute bearings. 




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. It is mounted to the forks by bolts 

ensuring the rigidity of the front wheel location. The lower fork brace is connected to the 

30mm longer longitudinal control arm by the typical Telelever maintenance free ball joint. 


15



The travel of the front wheel is damped by a 

central suspension strut with twin-sleeve 

damper principle. It provides 144 mm of 

front suspension travel. 

To review the changes in the chassis geometry 

we will compare the R 1200 C to the 

CL. But first lets review the basics of chassis 

geometry. 

Rake = The inclined angle that is created 

by an imaginary line through the steering 

pivots to the road surface. 

Trail = The distance, as measured along the 

ground, of the point at which the front tire 

contacts the ground and where the imaginary 

axis line of the steering pivots would 

contact the ground. 

By itself, the 30mm longer R 1200 CL 

Telelever changes the rake angle to 56 O 

and increases the wheelbase by the same 

distance. 

However, the new lower fork brace repositions 

the steering pivot further forward on 

the fork brace, which moves the forks rearward 

reducing the overall wheelbase but 

increases the trail. 

Final chassis specifications of R 1200 C 

vs R 1200 CL: 

Rake angle: 

C = 60.5 O 

CL = 56 O 

Trail measurement: 

C = 86mm (3.38“) 

CL = 184mm (7.24“) 

Wheelbase: 

C = 1650 mm (65.0“) 

CL = 1641 mm (64.61“) 

16 




The Monolever swing arm is fixed very rigidly 

– in central cast steel parts – in backlash 

free taper roller bearings, thereby resulting in 

a short, rigid connection between the bearing 

of the rear wheel swing arm and the longitudinal 

control arm. 

The welded monolever consists of extremely 

strong molded steel parts.The monolever 

has been structurally reinforced in the area 

of the spring strut support and the extruded 

sections. 

The swing arm is 612 mm long which has 

remained the same length in order to realize 

the seat position behind the rear wheel and 

the classical directional stability of a Cruiser. 

The forces of the Monolever spring strut are 

absorbed above the swinging arm bearing, 

which are distributed optimally in the tension 

struts of the frame triangle. 

The new spring strut is equipped with a single 

sleeve damper and the pre-load of the 

spring can be easily adjusted hydraulically 

with a hand adjustment knob. 

The rear wheel has 120 mm of travel. The 

damper system is identified as W.A.D., 

which is a german acronym for travel related 

dampening. 

This principle works in the compression 

stroke with a needle valve that closes off a 

fluid dampening section within the strut to 

increase damping when travel movement 

comes close to the end limits. 


17



The rear frame section is welded together 

by a combination of tubular, cast and forged 

steel components. The frame is then paint 

finish coated. 

Cast steel bearings for supporting the foot 

pegs of the rider and pillion are welded to 

the frame. 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. 

18 

Tail Frame Section 

Due to the longer seat system and the addition 

of the top case, the rear frame is 

lengthened accordingly. The side cases are 

mounted to tubular frame extensions providing 

a screw mounting point.The left side 

extension is removable for tire service by 

removing four screws. 

Front Wheel 




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. 

The wheel is screwed directly to the rear 

axle with four wheel-bolts enabling the 

wheel to be removed easily once the side 

case is removed or with a service lift with a 

removable floor. 

The front wheel measures 3.5 x 16 with tire 

measuring 150/80 VR 16 for the best braking 

efficiency and comfort. The front wheel 

axle is also new. It’s length has been 

increased due to the wider spacing. 

Removal of the rear wheel is simplified by 

the use of the accessory service stand jack 

and a detachable rear frame that is accessible 

from behind the left side saddle bag. 

The rear wheel can be removed without 

removing the side frame if the motorcycle is 

on a service lift with a removal rear wheel 

floor. 

• Detach the case 2 x T25 + 2 x T30 

• Case mount (frame section) 4 x T40 

• Rear wheel bolt 4 x M12 x 60. 

• Note the intermediate spacer. 


Front & Rear Wheels 

Frame Case Mount Removal/Installation 

Spacer Plate 

Rear Wheel Removal/Installation 

4 x T20 

Torque 

to 20 Nm 

when reinstalling 

105 Nm 

(cross pattern) 

19


Brake Components and Integral ABS 

The brake system has been designed to 

meet the demands of a touring Cruiser. The 

EVO brake and fully integral ABS are used 

for the first time on the R 1200 C model. 

The large 305mm floating brake discs made 

of high-grade steel are used on the front 

wheel. The bearings are connected directly 

to the hub of the front wheel by means of a 

secondary support and five screws. Drilled 

discs enhance the brake reaction in wet 

conditions and increase the self-cleaning 

effect. 

The two hydraulically operated 4-piston 

calipers are designed as fixed calipers providing 

angular wear compensation due to 

the offset piston diameters. The piston 

diameters are 36 or 32 mm. 

20 

The sintered metal brake pads have a brake 

pad surface of 86 cm 2 .The rear wheel brake 

is a hydraulically operated single disc brake 

with 4-piston caliper and organic brake 

pads. It has been taken over essentially 

from the K 1200 LT model. 

The floating high-grade steel brake disc 

screwed to the ring gear of the rear axle has 

retained the diameter of 285 mm. The thickness 

of the disc has been increased to 7 mm. 

A visual wear indicator is mounted on the 

steel support of the outer brake pad to 

make it easy to check the available pad 

thickness as the brakes where and as an 

indicator that they require replacement. 





New! 

Brake Pad Wear Indicator 

When the tab of the indicator 

touches the pad on the other 

side, replace the pads. 

21



The BMW fully integral ABS enables the 

braking efficiency to be distributed via electronic 

control ensuring optimal braking 

power is always available on each wheel. At 

the same time, influencing factors such as 

dynamic wheel load distribution, load and 

temperature of the brakes are taken into 

account. In addition, the system includes 

the antilock function so that a reliable braking 

function is available on the motorcycle. 

The system’s integrated brake booster 

keeps the operating force of the brake lever 

low for the rider. With the fully integral variant, 

the front and rear control circuits are 

connected by integral pistons in the pressure 

modulator that the front and rear wheel 

brakes are activated automatically when the 

hand lever or rear pedal are operated. 

22 

The fully integral pressure modulator of the 

R 1200 CL is installed beneath the tank.The 

brake fluid reservoirs for the front and rear 

wheel circuit are located in the pressure 

modulator as on all R series bikes. The 

brake fluid reservoir for the front control circuit 

is located in the hand lever master 

cylinder. The rear control circuit reservoir is 

connected to the brake pedal master cylinder 

via a feed line (green line in illustration). 

As with all versions of the Integral ABS, the 

modulator control valves are designed to 

provide the residual braking function, which 

connects the control circuits and wheel circuits 

via piston movement (hydraulic over 

hydraulic control). This safety feature 

ensures adequate brake function if the ignition 

is turned off or if the Integral ABS is 

defective. 




The other lines run as follows: 

• The orange line (actuating pressure) and 

the yellow line (brake actuator signal) run 

from the handbrake lever to the pressure 

modulator. 

• The orange line (actuating pressure) and 

the yellow line (brake actuator signal) run 

from the foot brake lever to the pressure 

modulator. Furthermore, the green line 

comes from the brake fluid reservoir to 

the foot brake cylinder. 

• The red lines run from the pressure modulator 

(wheel circuit) to the front wheel 

and rear wheel brake calipers. 

• The sensor signals (blue) come from the 

front and rear wheel to the controller. 

• The warning lights in the cockpit are controlled 

via the blue lines. 


The new light weight speed sensor trigger 

rings in combination with the active wheel 

speed sensors recognize wheel locking 

tendencies much faster than the previous 

analog inductive sensors. 

The speed sensor signals are input to the 

Integral ABS control module for continual 

processing and are also output to provide a 

speedometer signal for systems requiring 

accurate speed information such as the 

cruise control and speedometer. 

The system also monitors the function of 

the brake light and rear light and indicates 

their failure when necessary. If a rear light is 

defective, the dimmed brake light takes over 

its function. 

The general warning light and an ABS warning 

light are located in the cockpit for indicating 

possible defects or faults. 

23


Bodywork 

The front fairing integrated headlights 

give this motorcycle a very distinctive 

visual appeal. 

The fairing integrated mirrors (which also 

house the direction indicator lights), and the 

permanently fixed windshield, the 3-part 

fairing harmoniously combines Cruiser and 

tourer features, providing a new standard for 

luxury cruising. 

The tank and side trim panel parts are distinctive 

with the ergonomics of the knee 

angle and the aerodynamically optimized air 

outlets of the oil coolers which provide 

additional leg protection. 

24 

These combined features result in a casual, 

pleasant seating position, the anatomy of 

the knee angle being particularly distinguished 

in the area of the air filter cover. The 

painted wide rear fender emphasizes the 

bikes stretched lines. 

The front fairing attached to the handlebars 

protects effectively against disturbing wind 

pressure and turbulence. Transparent wind 

guide vanes attached to the fairing ensure 

that additional water and dirt is deflected 

mainly from the passenger. 



Bodywork 

There are two windshield versions; low and 

high.The US market will receive the low version 

as standard equipment. The high version 

can be purchased as an accessory. 

Both types are distinctive thanks to their 

functional design, which is cut lower in a 

curved arch in the rider’s field of vision. 


The advantage is not only an enhanced field 

of vision in wet and dusty conditions. But at 

high speeds in particular, the ingenious 

recess improves the protection in the area 

of the shoulder and provides added wind 

protection for the passenger. 

25


Bodywork 

The mirror housings are designed as aerodynamic 

hand protectors. They are ventilated 

at the rear in order to prevent turbulence 

from forming on the handlebar grips. The 

rear-view mirrors can be quickly removed 

from the fairing by means ball sockets (ie: K 

1200 LT, R 1150 RT). 

The fuel tank trim panels protect the rider’s 

legs against the air stream and have integrated 

rain deflectors built in by design 

(edges flair outward). 

The panels are hollow plastic covers that 

attach to sheet steel carriers by screws. 

The space between the colored covers and 

steel carries houses a portion of the motorcycles 

electronic equipment (left side: 

optional Anti Theft System, right side: cruise 

control module). The side trim panels do 

not have to be removed if the fuel tank is 

removed. 

The handlebars are made from a 3.5 mm 

thick steel tube and have a diameter of 

28mm. The surface is coated with hard 

chrome. Handlebar weights are fitted at the 

ends of the handlebars for damping vibration. 

Perfect seating comfort includes the feet 

too: Running boards made of forged aluminum 

and vibration decoupled for the rider 

by rubber bearings and wide passenger 

foot rests derived from the K 1200 LT guarantee 

good foothold, and combined with 

the pleasant knee angle, ensure relaxed riding. 

26 

The seats include optional heating elements 

(standard on the CLC). The boldly 

designed border of the upper passenger 

supporting straps makes the luggage 

bridge a real eye catcher. 

A special feature of the side cases is the 

one-hand closing concept. After pressing 

the lock cylinder in, the flush finger lift lever 

springs up to unlatch the cover. When 

closed, the case cover latching system 

evenly compresses the lid into the seal by 

four integrated tension rods. 

A same key lock set is equipped with the 

motorcycle allowing a single key to operate 

the ignition lock/steering lock, filler cap and 

luggage system. 

The luggage system is integrated into the 

overall appearance of the R 1200 CL. The 

top case with a volume of 45 litres providing 

plenty of space for luggage.The central 

handle easily operates the latch and locking 

system as on the K 1200 LT. The combined 

side case volume of approximately 63 litres 

brings the total lockable storage capacity of 

the R 1200 CL to 108 litres. 

Case Capacities: 

Top Case = 45 liter (1.59 cu ft) 

Left Case = 33 liters (1.16 cu ft) 

Right Case = 30 liters (1.06 cu ft) 



Bodywork 


27


Headlights 

The four round headlights have been integrated 

in a new arrangement never before 

used on a BMW Motorcycle. The headlamps 

are mounted to an adjustable support 

made of a synthetic material. 

They consist of two larger low beam headlights 

and two smaller high beam headlights 

positioned one on top of the other. 

The low beam headlights work with an H4light 

and can be readjusted from the front. 

The high beam headlights with H1-lights 

enable wide illumination of the road with 

their scattered light. 

The park lamps with 4-watt conventional 

bulbs are installed in the low beam headlights. 

All electric light bulbs can be 

replaced from the outside after removing 

each inner trim. 

28 

The beam distance can be adjusted to 

compensate for two up riding with the 

spring-loaded lever located on left side of 

fairing rear surface. For normal position, 

lever is up, to adjust flip down (as shown). 

Load compensation light beam adjustment lever 



Headlights 

Lever Positions: 

Horizontal: normal position (shown); Always 

adjust base setting of headlights with lever 

in this position. 

Flipped down: position for 2 up with luggage 

(shown on previous page). 

The adjustment screw found in the center of 

the load adjustment lever is used to establish 

the base headlight position of the total 

headlamp assembly. This screw simultaneously 

adjusts the vertical position of all four 

headlights. 


Base setting adjustment screw 

29


Cockpit and Instruments 

The central component in the cockpit is the 

instrument cluster with its three round 

gauges and the centrally located ignition 

lock. 

The instruments are housed in an aluminum 

cockpit-support that is mounted on the fork 

brace. The cover glass and functionally 

designed analog instruments feature 

chrome rings. The electronic tachometer is 

large and easily read. The analog clock, is 

mounted high and centered always in the 

rider’s field of vision. The time can be 

adjusted easily by using the large rubber 

pushbutton located on the right hand side 

of the clock. 

The speedometer’s integrated digital LCD 

display includes a mileage meter that can 

be reset with the left reset button. The 

mileage indicator retains the setting selected 

prior to switching off the ignition, i.e. 

odometer or trip meter. 

30 

The warning lamps and signal indicators in 

the three centrally located rows are LEDs. 

• Top: green turn signals, red engine oil 

pressure and battery charge indicators. 

• Middle: Two red ABS, green neutral and 

round red Anti Theft 

• Bottom: Yellow reserve fuel indicator that 

flashes when the level reaches 4 liters, a 

blue high beam and the yellow cruise 

control indicators 

The clutch and brake levers are adjustable 

in order to ensure better ergonomics.There 

is a two stage heated-grip flip switch (50 

and 100%) on the right side combination 

switch. 



Electrical Components 

3 

11 

The neatly arranged electrical system is 

located under the fuel tank and is the 

basis for operating the electrical components. 

In addition to the distribution system 

technology and high quality connectors, 

the new wiring harness provides the 

possibility of options such as the Anti 

Theft System to simply plug into wiring 

provisions. 

The Motronic control module is located 

above the central electrical control box. 

Different electrical accessories can be connected 

to the wiring harness via the preinstalled 

special accessory-terminal. 

The electronic speedometer is supplied 

with a processed speed signal from the 

Integral ABS control module.The turn signal 

indicator relay is also fed with the speed 

signal, which ensures that the direction 

indicator is reset after approx. 210 m and/or 

11 seconds. 


4 

1 

5 

2 

6 

7 

8 

9 

10 

Electrical components: 

1 Blinker/Flasher module 

2 Fuel level indicator 

dampening module 

3 High beam relay (yellow) 

4 Starter relay 

5 Low beam relay (yellow) 

6 ABS warning relay 

7 Motronic relay 

8 Fuel pump relay 

9 Horn relay 

10 Load Shed Relay 

11Terminal connection for 

Ignition and light switch 

Not pictured - located 

under starter relay is 

starting system diode 

The light-emitting diode for the reserve fuel 

is controlled via an electronic module, 

which has a time delay of 17 seconds. 

The alternator’s maximum output is 840 

Watt, of which 300 watts is available at 

engine idle speed.The compact battery has 

a capacity of 19 Ah. 

Cranking the engine is accomplished with 

an 1.1-kW planetary gear starter. Cranking is 

only possible when the gear box is in neutral 

or in gear with the clutch lever pulled in. 

Only then is there voltage on the coil of the 

ignition relay via the clutch lever and gear 

lever. Starting is only possible after the prop 

stand has been folded in. This is a typical 

safety feature of BMW. If a gear change is 

made when the side prop is folded out, then 

the Motronic relay is switched off. 

Two easily accessible fuse boxes with new 

mini fuses are arranged behind the left air 

filter cover. 

31


Cruise Control 

With the introduction of the R 1200 CL, 

cruise control is equipped for the first 

time on a BMW boxer. It is ideally suited 

for a luxury Cruiser, because it allows 

particularly relaxed riding both on interstates 

as well as secondary roads. 

The system electronics is carry over from 

the K 1200 LT. It is operated from the left 

combination switch. The system is turned 

on with the slide switch which also unlocks 

Set/ Resume pushbutton. 

A function light in the left combination 

switch also indicates that the system is 

ready. The SET LED in the central indicator 

display signals to the rider that the cruise 

control is activated. 

By pressing the pushbutton key in the forward 

direction, the current speed is stored 

in the control unit and kept adjusted to the 

accelerator cable by the cruise control.This 

is approx. 45 to 145 Km/h, which corresponds 

to 2/3 of the throttle valve opening. 

This is reset in the control unit by a stepper 

motor via an electromagnetic clutch and roll 

band. Thus, a fine adjustment of the speed 

is also possible. 

32 

This is done in intervals of approx. 1.6 km/h 

by tipping the pushbutton. 

• In the direction of SET: accelerate 

• In the direction of RES: decelerate 

If the SET function is deactivated, the last 

speed saved in the controller can be 

retrieved and set by pressing the pushbutton 

key in the direction of RES. 

The following operations cause the electromagnetic 

clutch to be switched off immediately 

thereby deactivating the cruise control: 

• Operating the brake or clutch 

• Turning back the throttle twist grip 

• Accelerating to more than 160 km/h 

• Setting the slide switch to OFF 

Cruise Control System Test: The cruise 

control system does not have a fault code 

memory. It does however convey functional 

confirmation through control of the SET 

indicator in the instrument cluster. This is 

known as the Cruise Control Self Test which 

can be done via MoDiTeC or by following 

the stand alone test on next page. 

When the SET indicator fails to change status 

in a phase of the test, it indicates a circuit 

problem in that area of the system. 

Refer to wiring diagram and check circuit(s) 

and components of circuit. 



1. With the ignition in the OFF position 

switch the cruise control switch to ON. 

Press and hold the cruise control button 

in the SET position and turn the ignition 

switch to ON. SET indicator goes ON. 

When you release the button the SET 

Indicator in the cluster goes OFF. 

2. Press and hold the cruise control button 

in the RESET position. SET indicator ON. 

Release button, SET indicator goes OFF. 

3. Switch the cruise control switch to OFF 

position. SET indicator goes ON. 

4. Switch the cruise control switch back to 

ON. SET indicator in the cluster goes OFF. 

5.Twist throttle grip back against detent 

until you feel click of microswitch. SET 

indicator goes ON. Release throttle grip. 

SET indicator in the cluster goes OFF. 


6. Pull clutch lever in fully. SET Indicator in 

cluster goes ON. Release, goes OFF. 

7. Pull front brake lever. SET indicator in 

cluster goes ON. Release, goes OFF. 

8. Repeat Step 7, but hold for 5 seconds 

until the SET indicator automatically goes 

OFF. Then release brake lever and remove 

hand from throttle. 

9. Once brake is released, the cruise control 

module activates the motor. Listen for 

a click. 

10. Rotate the rear wheel to generate a 

speed signal; SET indicator in cluster 

blinks Flashes ON and OFF. (Roll motorcycle 

on shop floor) 

Switch Ignition OFF, end of Test. 

33



The R 1200 CL uses a new cable control 

box to converge the operation of the throttle 

from either the opener/closer cables of 

the throttle grip or the control cable from 

the cruise control actuator. 

The box is located behind the fairing and 

headlight assembly both of which require 

removal to access. The box interconnects 

four cables with two pulleys. It also contains 

a microswitch that signals the cruise 

control module when the throttle is turned 

in the close direction to cancel cruise function 

The spring tensioned pulleys rotate on a 

shared axis. The lower pulley is attached to 

the opener cable, the closer cable and the 

throttle cable. The upper pulley is connected 

to the cruise control cable. 

The pulleys rotate freely from one another 

when the throttle is operated from the grip. 

In this function, the twist grip pulls the 

opener cable which simultaneously pulls 

the throttle cable at the lower pulley. 

When the cruise control actuator pulls the 

cruise cable, the upper pulley rotates. A pin 

on the upper pulley engages the lower pulley 

and simultaneously operates the throttle. 

The pin on the upper pulley and the slot on 

the lower pulley are keyed to allow full grip 

control to over ride the cruise control function. 

When the twist grip is turned in the 

opposite direction the closer cable is tensioned 

which activates the closer switch, 

signalling the cruise control to deactivate if 

currently active. 

There are four adjustment points on the 

cables to adjust cable play. They are at the 

twist grip and at the cable unions under the 

fairing just forward of the spring damper. 

34 

Closer cable 

Cruise cable 

Cable box location 

Cable Box internal view 

Opener cable 

Cable Box 

Throttle cable 





35


Sound and Communication System 

The R 1200 CLC is equipped with the Stereo 

Radio with Single Player CD as standard 

equipment. The Base R 1200 CL is prewired 

to accept the equipment as an accessory. 

The system consists of the combined radio 

electronics/single CD player located in the 

right side case, the radio controller on the 

left hand handlebar, and the centrally mounted 

display/control panel. The radio unit with 

RDS and a scan-function. 

The output stages for the loudspeakers can 

be controlled separately, enabling the sound 

to be distributed individually via the balance 

and fader. 

The two standard 20-watt loudspeaker units 

each consist of a broad-band loudspeaker. 

With regard to the best sound quality, these 

are contained in enclosed boxes with the 

same volume. 

36 

The sound system mounted on the handlebar 

clamp in the rider’s field of vision can be 

switched on and off in the central control 

panel with a digital display. 

All functions are selected via illuminated 

buttons. The rider can easily select the volume, 

radio stations, station finding, mutefunction 

and radio traffic service by operating 

the standard remote control on the left 

grip control. 

The station finding can be operated manually 

or automatically with two levels of sensitivity. 

The scan-function searches for the 

next station or title and plays it for ten seconds.The 

volume can be reduced by 20 dB 

with the mute-function. The CD-drive is 

operated electronically and can be used for 

normal audio CDs. 



Sound and Communication System 

The right side case also includes a cooling 

fan system for the electronics. The fan runs 

continuously whenever the Radio/CD is 

switched on. Make sure nothing obstructs 

the intake air grill around the fan when loading 

the right side case. 

A practical extension to the sound system 

is the newly developed BC-Voice (onboard 

communication system) available as a special 

accessory. The VOICE system module 

mounts beneath the radio, but is controlled 

by the radio control panel due to interconnection 

of the two systems. 

The connection terminals for the mobile 

telephone and radio are also inserted into 

the front panel of the BC-VOICE. 

Telephone calls can be received if the 

device has an automatic call receiver and if 

a small mobile radio telephone antenna is 

used. The radio connection is intended for 

Family Radio Band (Free Talk) two way 

radios. 

Look for accessory installation instructions 

for the BC VOICE system on MTAS. 

A new easily detachable dielectric rod 

antenna and base union are being introduced 

on the R 1200 CL. This new style 

union offers simplified removal and reinstallation 

when necessary for cover use. 

The antenna is decoupled from the base 

using an special tool found in the tool kit 

and unscrewing the union. The contact is 

more robust than previous antennas ensuring 

proper connection everytime. 


BC VOICE installed position / Cooling Fan 

Dieletric Antenna 

37


Technical Data 

Engine: 

Performance 

Max. torque 

Bore 

Stroke 

Effective capacity 

Stroke/bore ratio 

Compression ratio 

Fuel 

Angle of valve in relation to the cylinder axis 

Valve diameter Intake: 

Exhaust: 

Camshaft 

Valve timing at 3 mm valve play 

Valve stroke (without valve play) 

Engine oil volume 

Oil filter 

Oil pumps 

Lubricating Circuit Oil Pressure 

Engine cooling: 

Flow rate of the pump 

Start of opening of the thermostat valve 

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 

45 kW (61 hp) @ 5000 rpm 

98 Nm (71 ft/lb) @ 3000 rpm 

101 mm (3.98”) 

73 mm (2.87”) 

1170 cm 3 (71.4 cubic inches) 

0.72 

10.0 : 1 

Unleaded regular grade fuel, 95 RON 

Intake: 19° 

Exhaust: 22° 

34 mm (1.34”) 

29 mm (1.14”) 

256° 

Intake opens 17° ATDC 

Intake closes 15° ATDC 

Exhaust opens 15° BTDC 

Exhaust closes 17° BTDC 

8.23 mm (0.32”) 

3.75 liter (4 quarts) 

External filter cartridge 

2 Troichoid pumps from auxiliary shaft 

driven by a chain 

3.5–6.0 bar (50-87 psi) 

at 80° C (176 O F) oil temperature 

Combined air/oil cooling with twin coolers 

integrated in the frame. Circulation by 

means of separate oil pumps 

with thermostat control 

35 liters (37 qts) per minute 

95 °C (203 O F) 

38 Technical Features in Detail



Clutch: 

Clutch disc diameter 

Master cylinder piston diameter 

Slave cylinder piston diameter 

Gearbox: 

Primary input shaft gear reduction 

Gear Ratios 

Rear wheel drive: 

Transmission 

Ring/Pinion teeth 

Mixture control/ignition system: 

Maximum engine speed 

Idle speed 

Lambda control 

Fuel cut-off 

Fuel pressure 

Capacity of the fuel tank 

Ignition angle range (motronic controlled) 

Spark plug 

Generator: 

Maximum power 

Voltage 

Transmission 

Starter: 

Power 

Transmission of planetary gear 


Hydraulically operated single-disc dry 

clutch with transmission disc spring and 

asbestos-free friction lining 

165 mm (6.5”) 

13 mm (0.5”) 

24 mm (0.94”) 

Constant mesh 6-speed transmission 

integrated in flange-mounted case 

1:1.889 

1st gear: 1 : 2.038 

2nd gear: 1 : 1.600 

3rd gear: 1 : 1.267 

4th gear: 1 : 1.034 

5th gear: 1 : 0.903 

6th gear: 1 : 0.698 

Angular gear with Palloid tooth system 

1 : 2.62 

34/13 

Digital motor electronics: Motronic MA 2.4 

7000 rpm (disabling of the injection signal) 

900 rpm 

Engine temperature above 60° C (140 O F) 

Speed above 1800 rpm 

Engine temperature above 70 °C (158 O F) 

3.0 bar (43.5 psi) 

17.5 liters (4.62 gallons), including approximate 

4 liter (1 gallon) reserve (light on) 

+43° to 0° OT (characteristic zone) 

Bosch FR6 DDC 

Alternator with voltage control 

840 W 

14 V 

1 : 1.5 

With magneto-electrically excited electromotor, 

drives the clutch plate by means of 

intermediate gearbox and pre-engaged 

drive 

1.1 kW (1.5 hp) 

1: 5.5 

39



Front wheel suspension: 

Full spring travel on the wheel 

Stanchion diameter 

Steering lock angle 

Spring/Dampening 

Rear wheel suspension: 

Effective length of swing-arm 

Spring deflection on the wheel 

Damping system 

Wheels: 

Dimensions 

Tires: 

Dimensions 

Brake system: 

Front: 

Brake disc diameter 

Brake disc thickness 

Caliper piston diameters 


Brake pad friction material 

Rear: 

Brake disc diameter 

Brake disc thickness 

Caliper piston diameters 


Brake pad friction material 

Telelever with central strut and tilt decoupling 

of the upper fork brace 

144 mm (5.67”) 

35 mm (1.38”) 

35 ° right / left 

Strut with coil spring and twin-sleeve 

damper (non adjustable) 

Monolever with central strut, Steel swing 

arm and single-sleeve damper Spring preload 

adjustable hydraulically 

612 mm (24”) 

120 mm (4.72) 

WAD (Travel related damping on the compression 

stroke) 

Die-cast aluminum wheel, 5 double spokes 

Front: 3.50"x16" MTH2 

Rear: 4.00"x15" MTH2 

Light low-section Cruiser tire 

Front: 150/80 VR 16 

Rear: 170/80 VR 15 

Hydraulically operated, Standard I-ABS 

Double-disc brake with 4-piston fixed 

caliper, de-skew, floating high-grade steel 

brake discs 

305 mm (12.0”) 

5 mm (0.2”) 

32/36 mm 

16 mm (0.63”) 

Sintered metal 

4-piston fixed caliper, floating high-grade 

steel brake disc with asymmetrical bearings 

285 mm (11.2”) 

7 mm (0.27”) 

32/34 mm 

14.29 mm (0.56”) 

Semi-metal (organic) 

40 Technical Features in Detail



Dimensions: 

Overall length 

Width at the rear view mirrors 

Height at the top edge of the windshield 

Wheelbase in normal position 

Trail in normal position 

Steering head angle in normal position 

Seat height, unladen weight 

laden weight (187 lb rider) 

Ground clearance in normal position 

Weights: 

Unladen, road ready and fully fueled 

Permitted total weight (GAVR) 

Performance: 

Maximum speed 

Acceleration 0–100 km/h (0-62 MPH) 

Average fuel consumption for one hour of 

riding at a constant: 

• 90 km/h (55.9 mph) 

• 120 km/h (75.0 mph) 


2,415 mm (95.0” - or - 7.92’) 

1,075 mm (42.3”) 

1,435 mm (56.4”) 

1,641 mm (64.6”) 

184 mm (7.24”) 

56.5° 

755 mm (29.7”) 

745 mm (29.3”) 

159 mm (6.25”) 

308 kg (679.0 lbs) standard equipment 

530 kg (1,168.5 lbs) 

allows max rider, passenger and luggage 

weight of 222 kg (489.5 lbs) 

165 km/h (102.5 mph) 

6.3 s 

5.1 liters (1.34 gallons) 

6.2 liters (1.64 gallons) 

41


PDI Procedures - Uncrating 

Delivery and Crate Inspection 

While the motorcycle is being unloaded by the shipper, thoroughly inspect the 

crate for damage. Department of Transportation law requires the driver to allow 

you, the representative of your dealership ample time to perform a thoroughly 

crate inspection for each delivered unit. 

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). 

• Motorcycle Service Information Bulletins, Group 4 (Warranty). 

If any crate damaged is present: 

• Thoroughly examine the motorcycle and all contents for consequential damage 

or missing parts. 

• Clearly note damage and or missing parts on the truckers bill of lading (delivery 

slip). 

• Inform the trucking company in writing without delay. 

• Damage under $750.00 must be claimed via warranty. 

• Damage over $750.00 requires your field representative to be contacted. The 

field representative must authorize your claim prior to submittal. 

Crate Contents/Locations 

• Front Wheel • Key set (D) 

• Windshield (A) • Antenna (C) 

• Fender (B) • Mirrors (E) 

• Rider Manuals, Dealer Directory (I) 

• Pertinent attaching hardware (F) 

• Tool Kit (F) 

• Top Case (G) 

Start a Vehicle History File 

• Establish a Vehicle History File. 

• Remove the documentation on the 

side of the crate and place it into 

the file. 

42 





43



Lever off top cover and minimize for easy handling 

44 

Remove top plastic bag 

Carefully lever out top supports 

Uncrating the motorcycle 

• With the crate on a level surface, 

remove the top cover by levering it 

off with a pry bar. 

Hint: Place the crate top on the 

edge of the crate frame and snap it 

in half. This will make handling the 

cover more manageable. 

• Remove the plastic bag suspended 

between the crate lateral supports. 

Set the bag aside in a safe place. 

• Remove the antenna from right side 

crate support. 

• Pry or cut the lateral supports out 

from the top of the crate as shown. 

• Using a suitable saw such as a 

reciprocating saw (Sawzall TM ), carefully 

cut the sides of the crate 

where they attached to the end 

panels. 

• Do this on both sides of the crate 

(total of 8 cuts). 

Cut crate in 8 locations as shown (both sides) 




Note: During next three steps, ensure crate panels do not damage motorcycle. 

• Remove the front tire from the right side area of the crate and set it aside. 

• Remove both side panels from the crate base by carefully pivoting forward 

and backward until vertical brace detaches from base.You may also choose 

to cut the vertical braces at the bottom with someone assisting you. 

• Remove both crate end panels by forcibly pulling the panels from the crate 

base. Give a good yank, they will separate from the crate base quite easily. 

• Critical Step! Wipe down the brake 

rotors on both wheels with brake 

cleaner and a lintless rag. Make 

sure you also clean the disc surfaces 

beneath the pads on the rear 

wheel as soon as you can prior to 

operating brakes. 

• Remove the front straps first. The 

rear straps will hold the motorcycle 

upright on the crate base. Hint: 

Configure strap loop end as shown. 

Grasp the loop tightly and pull it 

away from the buckle. 

• Attach tie strap to handlebar/triple 

clamp fittings as shown. If equipped 

with radio, strap on outside of fork 

bridge clamps only. Do not damage 

radio control/display panel with 

strap. 

• Use special tool 90 88 6 465 640 

(crane) to lift the front end off the 

crate base. 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. 


Release Tie Down Straps Holding Bike to Base 

Lifting Front Axle, removing pallet and supporting 

45


PDI Procedures - Set Up 

• Clean area under motorcycle completely 

ensuring any sharp objects 

or nails are removed. 

• Install fender. Unbolt the calipers 

from the front forks. 

• Loosen fork leg pinch bolts (5 & 6). 

Remove axle bolt (4), axle (3), and 

spacer (2) from forks. 

• Ensure spacer seal (1) is positioned 

onto hub (opposite side as shown). 

• Coat axle lightly with Optimoly TA 

(Never seize). Position wheel into 

forks with spacer (2) in place and 

slide axle through the front wheel. 

• Align hole in axle so its parallel with 

the ground. Tighten axle bolt to 

specification. 

• Install the calipers. Take care not to 

scratch the rims when installing by 

rotating taped section of rim to area 

of calipers. 

• Torque all fasteners with exception 

of right fork pinch bolt (6). 

• With assistance, lower and remove 

crane. Remove rear straps and roll 

bike off crate. Put side stand down. 

• Sit on bike, apply front brake to hold 

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. 

46 

Install Fender 

Install wheel and calipers 

Torque Specifications: 

- Fender Bolts = 8 Nm (5.8 ft/lbs) 

- Axle/Nut = 30 Nm (22 ft/lbs) 

- Pinch Bolts = 20 Nm (15 ft/lbs) 

- Caliper Bolts = 30 Nm (22 ft/lbs) 




Caution: The R 1200 CL is equipped 

with Integral ABS and is in residual braking 

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. 

If the motorcycle is to be moved prior to 

battery installation, have someone assist 

you moving it through the shop and be 

extremely cautious. 

• Top Illustration. Remove the 

Instrument panel center trim (2) by 

removing securing screws (1). 

• Remove foam rubber barrier piece 

and place aside. 

• Middle Illustration. Assemble the 

windshield rubber trim seal (1) at 

base of windshield as shown. Use a 

soapy water solution to piece the 

two parts together ensuring an even 

installation. 

• Mount windshield/seal assembly 

onto fairing area mounting using for 

screws (2). 

• Make sure seal is evenly spaced on 

fairing surface. 

• Bottom Illustration. Reinstall rubber 

barrier piece (3) and place instrument 

panel trim (2) into position. 

• Inspect all the mating surfaces for 

smooth fit. Secure with six screws 

(1). 


Remove Instrument Panel Trim 

Assemble windshield/seal and install 

Install Instrument Panel Trim 

47



• The handlebars are lowered to 

allow the motorcycle to fit into the 

crate for shipping. HANDLEBARS 

MUST BE ADJUSTED OR DAMAGE 

TO THE FUEL CAP MAY RESULT. 

• Loosen bar clamps on upper fork 

bridge. Raise bars until dimpled 

spot on bar is equal to mating surface 

of bar clamp and fork bridge. 

• Properly adjusted, bars should not 

be closer than 3 - 5mm to fuel filler 

door when open and bars full right. 

Torque bolts to 19 Nm (14 ft/lbs). 

• Hold mirror up to fairing mount 

location. Connect directional light 

connector (1) into wiring plug in fairing. 

• Align ball socket unions and press 

(snap) mirrors into place. 

• Locate case in shipping carton and 

prepare for installation. To remove 

interior covering, unscrew case top 

stop strap knurled screw anchor 

(3). Use a small screwdriver and 

press tabs (2) clear of stops and 

remove covering (ie: K 1200 LT). 

• Use shipping screws to install case 

to four mounting base threaded 

bores (1). The case mounts identically 

to K 1200 LT model. 

• Reinstall covering and reattach top 

case stop strap and knurled screw 

anchor. 

48 

Adjust Handlebars 

Install Mirrors 

Install Top Case 




• 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 O bend phillips head screw 

driver socket for removing rear 

directional light lens covers. 

• Radio Antenna wrench 

• Install Antenna using special tool as 

shown (from tool kit). 

• Thoroughly wash motorcycle to 

remove all transportation preservatives. 

• Inspect the motorcycle thoroughly 

for damage and or missing parts. If 

necessary, submit a QEW (MTAS). 

• If parts are needed, order them. 

Part costs are reimbursed via a 

warranty claim using defect codes: 

Parts missing - 10 01 00 00 00 

Parts damaged- 10 02 00 00 00 

Parts Incorrect - 10 03 00 00 00 


Make sure tool kit is complete 

Install Antenna 

• At this point you have completed the set up portion of the Pre Delivery 

Inspection. Make sure an RO has been assigned to the PDI for the motorcycle 

and convey any information about missing or damaged parts to the 

parts department and warranty administrator. 

• Perform balance of Pre-delivery inspection checks as outlined on the Predelivery 

check sheet sample on the next page. PDI checklists are accessed 

online from the MTAS (Aftersales> Service> Technical Information). As a 

time saving tip, print out multiple copies and store them for future R 

1200 C models. 

49


PDI Checklist Sample 

50 


Pre-delivery check 

�R 1150 R �R 1100 S �R 1150 RT �R 1150 GS �R 1200 C �R 1200 CL 

_______________________ ___________________ 

Customer Name Serial Number / Mileage 

_______________________ ___________________ 

Repair Order Number / Date Technician Signature 

Inspect crate on receipt for signs of damage, start vehicle history file 

Uncrating the motorcycle 

- Remove document package from crate wrap 

- Unpack and check for missing items; complete QEW if needed for missing parts 

- Clean brake rotors prior to moving from crate 

- Complete assembly using BMW uncrating and assembly instructions 

(Have assistance moving an Integral ABS equipped motorcycle prior to battery connection) 

- Adjust Handlebars to prevent damage of fuel filler door (R 1200 CL) 

- Equalize pressure in front forks (R1100S) 

- Clean entire motorcycle of transport preservatives 

Check complete specification delivery: 

- Keys,Tools, Handbooks and documents (including warranty information) 

- Retailer directory/retailer business cards 

- Documentation for installed options 

Battery: 

- Remove battery 

- Add battery acid 

- Allow battery to cool prior to charging 

- Charge battery at 10% AH rating until fully charged 

- Grease the terminal posts 

- mark in service date 

Check and adjust front and rear brake fluid levels. 

Integral ABS equipped - check brake fluid level at the modulator. 

Integral ABS equipped - Perform bleed test with BMWMoDiTeC 

(Print test results, attach to RO and file in Vehicle History File) 

Check function of side stand safety function 

Check and adjust rear shock preload basic setting 

Check torque setting of the rear wheel retaining bolts _______lb/ft 

Adjust tire pressures to specification - Front ______PSI, Rear ______PSI 

Check engine oil level, correct if necessary 

Check clutch fluid, correct if necessary 

Check headlamp (basic setting), correct if necessary 

Fuel the motorcycle (full tank of fuel prior to customer delivery) 

Safety / operating check as final inspection: 

- Cold start / idle speed 

- Clutch, gear shifting, - Steering 

- Front / rear brakes and ABS 

- Indicator and warning lights, instruments, lighting, horn and signalling equipment 

- Check function of Cruise Control (R 1200 CL) 

- Function of optional equipment (radio, alarm, etc.) 

- Test ride 15 miles, check for fluid leaks 

- Visual quality check 

BMW 

Pre-delivery Inspection 



PDI Procedures - Accessing Battery 

• With an assistant, place motorcycle 

onto the auxiliary center stand. 

Make sure pins fit securely into 

bracket holes under engine. 

The fit tolerance is close on pins. If 

resistance is encountered, gently 

tap pins into holes with a plastic 

mallet. Press button (1) to retract 

check balls and push pins in fully. 

• Remove the riders seat (two nuts 

and washers under seat on left and 

right side). 

• Remove Left and Right Side 

chrome intake pipe covers. 


Lift bike with auxiliary stand 

Remove Front Seat 

Remove Left and Right Intake Covers 

51


PDI Procedures - Accessing Battery 

• Remove both Left and Right side 

painted trim covers (2) by removing 

two screws (1). 

• Remove fuel tank mounting bolts 

and washers (1). 

• Gently lift rear of tank and unplug 

fuel pump connector (4) 

• Disconnect two breather lines (3). 

Note orientation and routing for 

reinstallation. 

• Release the quick disconnect fuel 

lines (2) by pressing the release 

catch (5) on each fitting. 

• Handle the fuel tank gently to prevent 

paint damage. Lift the fuel tank 

at the rear and pull backward to 

remove from forward mounts. 

Note: The fuel system quick disconnect 

fittings are sealed by an O’ring which can 

be damaged if the fitting is not reinstalled 

correctly. 

Always inspect the seal for damage prior 

to reconnecting this fitting. Always reset 

the latch plates on the female half of each 

union so the two halves can reconnect. 

When reconnecting, gently slide the two 

halves together squarely until an audible 

click is heard. Always visually check the fitting 

as well to ensure the union is sealed. 

If the O’ring needs replacement order only 

the O’ring which is available separately. 

O’ring P/N = 13 31 7 659 110 

52 

Remove Left and Right side covers 

5 

Remove Front Seat 

Remove Left and Right Intake Covers 



PDI Procedures - Removing, Filling and Charging Battery 

Note: Various models will eventually be 

factory equipped with a GEL CELL 

type battery. When this change over 

occurs, this PDI procedure will be 

revised. Please refer to appropriate 

Service Bulletin and or Battery 

Information Sheet located in Technical 

Training Section of MTAS. 

• Remove battery breather tube and 

hold down bracket. 

• Lift battery out of tray. Remove battery and fill with electrolyte 

Warning: Battery electrolyte is acid and is extremely caustic. Protect your eyes, 

face, hands, clothing and protect the motorcycle paint work. 

• Fill the battery with electrolyte, replace the caps, 

and let stand for one hour. 

• Remove air bubbles and top off with more electrolyte 

if necessary. 

• Charge the battery for 10 hours at a 2 amp rating. Use the appropriate charging 

system, do not use a maintenance trickle charger. 

• Let battery stand for 24 hours before testing the battery. 

• Specific gravity of the electrolyte in a fully charged battery should measure 

1.26 or above in each cell. This measurement is taken with a high quality battery 

hydrometer. 

• Mark the date on the battery. 

• Make sure the ignition is turned off. 

• 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 battery 

terminal posts. 


Electrolyte = 

• 35% Sulfuric Acid, 

• 65% Water 

Specific gravity = 1.28 

Mark the Service Date on the Battery Label 

53


PDI Procedures - Checking Brake Fluid Levels 

Integral ABS has four separate brake 

circuits. Fluid levels are checked at all 

four of the following locations, 

1. Handlebar mounted ffrroonntt brake 

control circuit reservoir. 

54 

• Turn handlebars fully to the left. 

• Check fluid level in sight glass. 

• MIN level is as indicated. 

• Top off with DOT 4 brake fluid as 

necessary. 

2. Right side frame mounted rreeaarr 

brake control circuit reservoir. 

• With the motorcycle on its center 

stand, check the level 

through the window in the right 

side trim panel 

• Desired level is at the MAX line. 

If necessary, add DOT 4 brake 

fluid.The fluid level must not fall 

below the MIN line. 

Note: Fluid level remains constant in 

control circuit reservoirs as pads wear. 

Checking Front Brake Control Circuit Fluid Level 

Checking Rear Brake Control Circuit Fluid Level 

3. Integral ABS modulator ffrroonntt brake wheel circuit reservoir 

4. Integral ABS modulator rreeaarr brake wheel circuit reservoir 

• Checking the fluid level at these two locations is identical in process. 

• Unscrew and remove the wheel circuit reservoir caps one at a time. 

• 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. 



PDI Procedures - Checking Brake Fluid Levels 


55


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 comprehensive 

ABS bleed test using the MoDiTeC is required as part of the PDI 

process prior to any operation of the vehicle. 

During the test, the MoDiTeC prompts you to individually apply the brakes at the 

front lever and rear pedal. The Integral ABS control module monitors the pressures 

generated in the control and wheel circuits. The MoDiTeC program compares 

the generated pressures to a specific value. If the generated pressures 

are within specification, the system passes. If not, the system fails. 

During the test a large amount of data is read out from the control module. As 

a record of the test being carried out, the documentation generated by the completion 

of this test must be printed out and kept in the vehicle history file. 

Bleed Test Requirements 

Prior to performing Bleed Test, make sure the following preconditions are met: 

• Up to date MoDiTeC software must always be loaded. 

• Motorcycle battery must be fully charged. 

• Battery charger must be connected to motorcycle. 

• From the Integral ABS Toolbox, launch the bleed test program. Follow all 

onscreen instructions. 

• Printout and sign your name and date to the successful bleed test results and 

insert into vehicle history file. 

If you encounter problems that can not be rectified either with bleed test or bleed 

procedure please contact the Integral ABS Hotline. 

Integral ABS Hotline: 1 888-217-9725 (Monday-Friday, 8:30am - 4:30pm EST). 

56 

Important ! 

If the motorcycle fails this bleed test during the PDI, the reported failed circuit 

will require bleeding. Refer to the appropriate repair manual and training manuals 

for for system bleeding instructions. 

This motorcycle shall not be test ridden, retailed, traded, or in any way 

demonstrated, or handed over to, the retail customer until a successful bleed 

test printout for the motorcycle is placed into the vehicle history file. 



PDI Procedures - Check Engine Oil Level 

The engine is factory filled with oil and 

only requires a visual check at the 

sight glass. As long as oil level is visible, 

it is ok for PDI test ride. However oil 

level must be checked prior to customer 

delivery as follows: 

• Engine must be run to operating 

temperatures and then allowed to 

sit with engine off for 5 minutes 

allowing oil to drain back to sump. 

• With motorcycle in upright position, 

level should be between Max/Min. 

The difference between the marks 

MAX and MIN is approx. 0.53 qt. 

If necessary top off through filler. 

Check Clutch Operating Fluid 

• With motorcycle on center stand, 

turn the handlebar fully to the right. 

• Desired fluid level when clutch lining 

is new is center of sight glass. 

• If necessary, add DOT 4 brake fluid. 

Note: Fluid level will increase as the 

clutch plate wears. Fluid level must not 

fall below minimum (center dot). 

Check tire pressures 

Tire pressures are same for all conditions 

(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. 


Checking Engine Oil Level 

Checking Clutch Operating Fluid Level 

Battery: 

- Remove battery 

- Add battery acid 

- Allow battery to cool prior to charging 

- Charge battery at 10% AH rating until fully charged 

- Grease the terminal posts 

- mark in service date 

Integral ABS equipped - Perform bleed test with MoD 

Check function of side stand safety function 

Check headlamp (basic setting), adjust if necessary 

36 42 

Check torque setting of the rear wheel retaining bolts _ 

Check tire pressures - set at ______PSI front, ______PS 

Check and adjust front and rear brake fluid levels 

Check engine oil level, top up if necessary 

f cessary 

Record measured Tire Pressures 

57


PDI Procedures - Check Side Stand Function 

Check Side Stand Operation 

• Check for smooth side stand movement. 

Add BMW Lube if necessary 

(arrow). 

• Check side stand safety function. 

With transmission in gear and ignition 

key on, raise side stand to up 

position and listen for audible fuel 

pump operation cycle. This signifies 

proper safety operation. 

Rear Spring Preload 

• Turn knob fully out counter clockwise 

(to low position). 

Basic Setting (solo): Turn knob in to 

first increment line (red dot). 

Setting for two up/luggage: Turn knob 

in to High setting increment line. 

Check rear wheel stud torque 

• 105 Nm (76 Ft lb.) 

• Record your verified torque value 

on the PDI Check List. 

58 

Check Side Stand Operation 

Red Dot = Solo Position 

Shock Absorber 

Spring Preload Knob 

Rear Shock Spring Preload Adjustment 



PDI Procedures - Check Headlight Alignment 

• Set the shock preload to solo mode. 

• Place adjustment lever to the horizontal 

normal position (on back of 

fairing). 

• Check / set the tire inflation pressure. 

• Place the motorcycle on a flat surface. 

• A rider weighing 85 kg (187lbs) must sit on the motorcycle. 

• Measure the distance H from the floor to the low beam headlights center. 

• Mark the measured distance H on the wall. 


1=Left/Right, 2=Up/Down for each low beam 

• Then place two crosses on H line that are spaced the same distance that the 

two low beams are (S in Diagram) which is approximately 30 cm (11 3/4”). 

• Measure 15mm beneath the H line and mark another cross as well on this line. 

• With bike upright and low beam lights on only, check that transition of beams 

divide between light and dark as shown in diagram on the two crosses 

between the two lines. 

• If necessary, use the single screw on the back of the fairing to move total light 

assembly up or down to meet this line. 

• 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. 

59


PDI Procedures - Final Inspections and Function Checks 

Fill Fuel Tank 

• Fill the fuel tank with premium unleaded gasoline 

• Thoroughly check for leaks. 

Check the operation of the following: 

• Clutch & gearshift operation. 

• Steering (smooth, not binding). 

• Front & rear brakes. 

• Cruise Control Operation 

• Alarm System (if equipped) 

• Tail light, stop light, and turn signals. 

• Horn operation. 

• Test ride (14 - 16 miles). 

• ABS brake operation. 

• Idle speed (after the test ride). 

• Rubber stamp, sign, and date the PDI block in the Service & Technical 

Booklet. 

• Make sure the PDI Check List is completed with your signature. 

• 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. 

60 

Final Cleaning 



Retail Delivery Handover Process 

• The customer delivery process or“handover” is a critical step in establishing 

a successful relationship between you and your new customer. A positive 

delivery experience reinforces the image of your Dealership and the 

people who run it. Be prepared for the delivery by reviewing the sample 

Retail Delivery Check List on the following pages. 

• Retail Delivery Check Lists are accessed online from the MTAS 

(Aftersales> Service> Technical Information). As a time saving tip, print out 

multiple copies and store them for readiness when you are delivering your 

next motorcycle. 

• Familiarize yourself with the Rider Manual and Technical Book. These contain 

information the customer reads to become familiar with his or her new 

bike. Review these books at time of delivery, showing run in requirements, 

important basic safety information, as well as explaining maintenance 

requirements and scheduling for their 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. 


61


Retail Delivery Check List Sample, Page 1 

62 



Retail Delivery Check List Sample, Page 2 


63


600 Mile Inspection Procedures 

Note: This manual only includes the 600 Mile Service Procedures solely as 

an introduction convenience. For complete service maintenance procedures, 

always refer to the official factory service manual. Repair Manuals for all current 

models are located in MTAS, http://www.bmwmc.net (Aftersales> Service>Technical 

Information). 

Key to maintenance intervals 

Maintenance tasks consist of the first Inspection (after 

the first 1,000 km/600 miles), the BMW Service, BMW 

Inspection and BMW Annual Service. 

Inspection 1,000 km (600 miles) 

BMW Running-in Check after the 

first 1,000 km (600 miles). 

BMW Service 

After the first 10,000 km (6,000 miles) and each 

additional 20,000 km (12,000 miles) 

(at 30,000 km ... 50,000 km ... 70,000 km) 

(at 18,000 miles ... 30,000 miles ... 42,000 miles). 

BMW Inspection 

After the first 20,000 km (12,000 miles) and each 

additional 20,000 km (12,000 miles) 

(at 40,000 km ... 60,000 km ... 80,000 km) 

(at 24,000 miles ... 36,000 miles ... 48,000 miles). 

BMW Annual Service 

Certain maintenance tasks depend on elapsed 

time as well as the distance the motorcycle has 

covered.They should therefore be carried out at 

least once a year (e. g. changing brake fluid). 

If these tasks cannot be carried out during a 

Service or an Inspection, a BMW Annual Service 

must be performed. 

64 

Maintenance Schedule Checklist 

In this Repair Manual, the individual maintenance intervals 

are shown by the following codes: 

— Inspection at 1,000 km (600 miles)......................I 

— BMW Service at 10,000 km (6,000 miles)...........II 

— BMW Inspection at 20,000 km (12,000 miles) .. III 

— BMW Annual Service........................................ IV 

• The Maintenance Schedule Checklist is used to make sure all the maintenance is carried 

out at the proper time. The checklists are displayed on pages 66 and 67 to alert you of 

new procedures necessary on the R 1200 CL. 

• All current model Maintenance Schedule Checklists are accessed online from the MTAS 

(Aftersales> Service> Technical Information). As a time saving tip, print out multiple 

copies and store them for readiness. 



US Market Service Lubricants, Sealants and Thread Lockers 


65


Maintenance Schedule Checklist, Page 1 

66 


Maintenance Schedule 

�R 1100 S �R 1150 GS �R 1150 R �R 1150 RS 

�R 1150 RT �R 1200 C/CL 

_________________________ _______________________ 

Customer Name Repair Order Number / Date 

_________________________ _______________________ 

Vehicle Identification Number (VIN) Mileage In 

Check Vehicle History for any outstanding recalls. 

Read Motronic fault memories with BMWMoDiTeC 

• Integral ABS equipped - Perform bleed test with BMWMoDiTeC. 


Check Brake pads and discs for wear, renew as necessary* 

Check condition of tires 

Check ABS sensors/pulse wheels for correct gap/contamination 

Adjust and clean as required * 

Check front/rear brake fluid levels, top up if necessary* 

Check brake system with regard to function, leaks, repair as required * 

• Non ABS & ABS II ONLY - Change brake fluid once a year with DOT 4 

Fluid.* 

• Integral ABS equipped - Replace brake fluid in wheel circuit once a 

year (DOT 4).* 

• Integral ABS equipped - Replace brake fluid in control circuit every 2 

years (DOT 4).* 

• Integral ABS equipped - Perform bleed test with BMWMoDiTeC. 


Check clutch operating fluid level. (fluid level increases as clutch wears) 

Change clutch operating fluid every 2 years (DOT 4 brake fluid).* 

Re-torque cylinder head nuts (torque to 20 Nm, then 180O ) 

Check/adjust valve clearances 

Check condition of spark plugs 

Replace spark plugs 

Change engine oil when at operating temperature, renew oil filter. 

(for short distance driving or when outside temperature is below 32 F every 3 months or 1800 miles.) 

Change transmission oil when at operating temperature. (or every 2 years at the latest) 

Change oil in rear drive when at operating temperature. (or every 2 years at the latest) 

Non ABS & ABS II Only- Clean inductive speed sensor at rear drive. (or every 2 

years at the latest) R 1200 C, R 1100 S 

Check/adjust throttle cable play; any sticking, abrasion, tightness; replace* 

* invoiced as a separate item 

� Continue on page 2 � 


600 miles 

BMW Service 

6,000 miles 


12,000 miles 

BMW 

Annual Service 

Page 1 of 2 



Maintenance Schedule Checklist, Page 2 


Maintenance Schedule (Continued) 

�R 1100 S �R 1150 GS �R 1150 R �R 1150 RS 

�R 1150 RT �R 1200 C 

Vehicle Identification Number (VIN) 

Retension poly-V-belt 

Re-adjust new poly-V-belt one time at 6,000 miles 

Replace poly-V-belt* 

Replace poly-V-belt every 36,000 miles 

Renew fuel filter every 24,000 miles*; if fuel quality is poor every 12,000 miles. 

Check battery acid level, top up with distilled water if necessary; grease 

battery terminal posts. 

Renew intake air filter (if riding in dirty/dusty conditions every 6,000 miles/check more frequently) 

Check torque of the rear wheel retaining bolts_______Lb/ft _____Nm. (76 lb/ft 

105Nm) 

Check play in Telelever, wheel and swingarm bearings, renew if necessary. 

(replace wheel and swing arm bearings every 25,000 miles*) 

Adjust tire pressure to specification: Front _____ PSI Rear ______ PSI 

Grease side stand/center stand pivots 

Check for smooth operation of throttle butterflies, tighten hose clamps to 

eliminate possibility of air leaks, synchronize throttle valves and adjust idle. 

Final inspection with safety/operating check: 

• Lights, brake light, turn indicators, horn 

• Telltale and warning lights 

• Clutch, gear/neutral and side stand switch functions 

• Handbrake, footbrake and ABS; steering 

• 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 

Technician Signature Date Mileage Out 



600miles 

BMW Service 

6,000miles 

� Maintenance Complete, Sign and Record Mileage Below � 


12,000miles 

BMW 

Annual Service 

9/02 

67


BMW Inspection I Procedures (600 Miles) 

Check Vehicle History for outstanding 

Recalls using BMW DCSnet 

BMW inspections/services I, II, III, IV 

• www.bmwdcsnet.com/dcsnet 

Check Motronic and ABS fault 

memories with MoDiTeC 


• Connect MoDiTeC to diagnostic 

plug. 

• Read the fault memories of each 

system. Print out trace report and 

place into history file as proof completion. 

• If faults are logged, contact owner 

for approval. When advised, perform 

any diagnosis and repair work 

as necessary. 

Check Brake Fluid Levels and perform 

Integral ABS Bleed Test 


• Refer to procedure on page 54 of 

this manual. 

Check Tires 


• Check tire sidewalls and tread 

grooves 

• Check Tire Pressures. Tire pressures 

are same for all conditions 

(solo, 2-up, & 2-up with luggage). 

68 

Front: 2.5 bar (36.25 psi) 

Rear: 2.9 bar (42.05 psi) 

Check ABS sensors and pulse 

wheels for correct gap/contamination 


• Adjust and clean as required 

• Speed sensor gap 0.2-1.5mm 

Check Clutch Operating Fluid 


• With motorcycle on center stand, 

turn the handlebar fully to the right. 

• Desired fluid level when clutch lining 

is new is center of sight glass. 

Check Clutch Fluid Level 

• If necessary, add DOT 4 brake fluid. 

Note: Fluid level will increase as the 

clutch plate wears. Fluid level must not 

fall below minimum (center dot). If a 

large amount of fluid is needed to 

bring level up, consider the possibility 

of a leak in the hydraulic actuating system. 




Re-torque cylinder head 

Inspection I (600 Mi. only) 

• Remove ignition coils using new special tool 12 3 561 

• Remove cylinder head covers. Caution: catch draining oil. 

• Do not remove spark plugs. 

• Set engine to OT (TDC) by turning the crankshaft with wrench or by placing 

in 3rd gear and rotating the rear wheel. 

• The OT will be visible in the inside window as shown 

• Loosen one cylinder head nut at a time. Loosen nut further by hand and oil 

threads with engine oil. 

• Retighten to: 20 Nm (14 ft. lb.) - Additionally, angle torque: 180 O. 

• Re-torque the remaining 3 cylinder head nuts in a crosswise pattern in the 

same manner. 

• Loosen and re-torque the M10 bolt: 40 Nm (29 FT. LB.) 

• Repeat on opposite side 


69



Checking / adjusting valve clearance 


• Check valve clearances with two 

feeler gauges simultaneously and 

engine temperature below 95 O F. 

• Adjust clearance if necessary 

Caution: Make sure gaskets are 

seated correctly, the center gasket 

may have a wear pattern, install in 

same position as it was removed. 

• Reinstall all components and torque 

to specification. 

70 

Check Valve Clearances, Adjust if necessary 

Valve Clearances: 

Intake 0.15 mm (0.006 in.) 

Exhaust 0.30 mm (0.012 in.) 

Tightening torque: 

Adjuster lock nut, 8 Nm (6 ft. lb.) 

Cylinder head cover, 8 Nm (6 ft. lb.) 




Changing Engine Oil & Filter 


Note: Drain oil with engine at operating 

temperature. 

• Remove fill plug. 

• Unscrew oil drain plug & drain oil. 

• Fit oil drain screw plug with new 

sealing ring. 

• Using oil filter wrench, P/N 88 88 6 

11 4 650, unscrew oil filter. 

• Coat sealing ring of new oil filter 

with oil and screw in. 

• Fill the new oil filter with oil and, 

install. 

• Recheck oil level approx. 10 minutes 

after test run. 

Important: Never top up engine oil 

above ‘MAX’ mark. 


Change Engine Oil and Filter 

Add new to proper level (do not overfill) 

Filling capacity, engine: 

With oil filter change 4 qt. 

Without filter change 3.7 qt. 

Oil capacity between min and max 

marks app. 0.5 liter (.53 qt) 


Oil filter 11 Nm (8 ft. lb.) 

Oil drain plug 32 Nm (23 ft. lb.) 

Engine oil grades: 

Brand-name HD oil for petrol engines of 

API classification SG/SH 

71



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. 

• Screw in oil filler plug with new sealing 

ring. 

Check throttle cables for kinks, 

abrasion and verify smooth operation 

- replace if necessary 


• Inspect cables for external wear or 

breaks in casing from rubbing on 

other components. 

• Turn handlebars to full lock left and 

right while operating throttle twist 

grip. If abnormalities in “twist grip 

feel” are present, determine location 

of binding and repair. 

• Ensure throttle twist grip “snaps” 

back to closed position when held 

in open position and released. 

• Do not lubricate cables! They are 

designed to operate dry. 

72 

Rear Drive Oil Change 

Filling capacity: 

Rear wheel drive up to bottom edge 

of filler opening 0.25 Liter 

Transmission oil grade: 

Brand-name Hypoid gear oil of SAE 

90 API Class GL 5 


Oil drain plug, 23 Nm (17 ft. lb.) 

Oil filler plug, 23 Nm (17 ft. lb.) 




Check throttle/cruise control cables 

play - adjust only if necessary. 


- Only with cold engine (< 35 O C / 95 O F). 

• Switch Ignition on to allow the idle 

control motor to position the throttle 

plates for cold engine starting. 

• Rotate throttle grip to full open, 

return to idle, then twist further in 

closed direction, listen for cruise 

control closer cable switch “click”. 

You should also feel detent. 

• Return grip to normal idle position, 

Preset cable end play at adjusters 

for opener cable (1) and closer cable 

(2). (APPROXIMATE VALUES) 

Opener cable (1) = 7mm 

Closer cable (2) = 1mm 

• Remove plastic throttle cable covering 

(detail in top illustration). Twist 

throttle backward to activate switch. 

Measure distance of notch and 

stop. Must be 3mm or more. Use 

closer cable adjuster (2) to achieve 

distance if necessary. 

• Adjust clamping sleeves for cruise 

control and throttle cables located 

behind fairing as shown. 

Cruise Control cable = 2-3 mm 

Throttle Cable = 3.0 mm 

As the engine warms up to operating 

temperature, the throttle cable play will 

reduce to approximately 1mm 

Check cables for smoothness as you 

turn bars from left to right. Check function 

of cruise control system by performing 

self test (see page 33). 


Cable Adjustment Points 

Closer Cable twist grip measurement 

Adjusters 

Throttle cable 

3 mm or more 

Cable Adjustment pOints 

Cruise cable 

73



Torque Rear Wheel bolts 

BMW inspections/services I 

• Tighten the rear wheel studs in a 

crosswise pattern. 


Rear wheel studs; 105 Nm (77 ft. lb.) 

Check the rear drive, wheel, and 

swing arm bearings for play 

BMW inspections/services I, III 

• With motorcycle on accessory 

stand, rock the rear wheel side to 

side. Look for play at the rear drive, 

wheel and swing arm bearings. 

• If play is detected at any of these 

locations, isolate and repair. 

If play is detected at swing arm, retorque 

swing arm bearing 

74 


Bearing journal for rocker at right 

side frame, 9 Nm (6.5 ft. lb.) 

Bearing journal for rocker at right 

side frame, 7 Nm (5.0 ft. lb.) 

Lock Nut for bearing journal rocker 

160 Nm (115.0 ft. lb.) 




Check throttle synchronization values 

with MoDiTeC 


Note: The R 1200 CL has a common 

throttle linkage system and an Idle 

Control management feature of 

Motronic. These two features have 

deemed the throttle synchronization 

useless on the R 1200 C/CL models. 

However, as a measure of quality service, 

the throttle sync should be 

checked solely to ensure the system is 

free of air leaks that could lead to 

engine poor performance issues and 

customer dissatisfaction. 

• Connect Synchro unit to intake vacuum 

ports and MoDiTeC. 

• Engine should not run longer than 

10 minutes while stationary. Have a 

fan running to cool engine. Do not 

leave unattended. 

• The max difference should not 

exceed 0.3 bar as displayed by 

MoDiTeC. 

If excessive difference is present, it is 

most likely an intake air leak which 

must be repaired. 


Throttle Synchronization Test 

75



Final Inspection with road safety 

and function check 


Check the operation of the following: 


• Steering. 

• Front & rear brakes. 


• Cruise Control 

• Tail light, stop light, and turn signals. 

• Horn operation. 

• Test ride (14 - 16 miles). 

• ABS brake operation. 

• Idle speed (after the test ride). 

• Radio/ sound system 

• Complete the Proof of Ownership 

section in the Service & Technical 

Booklet. 

76 



Service & Maintenance Data 

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77


New Special Tools - Part of Automatic Initial Tool Shipment 

The special tools outlined on the following pages are service maintenance 

requirements. 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 initial 

tool package are additional tools for F 650 CS and the latest SD ROM (9/02). 

Part Number Designation / purpose 

Special tools for R 1200 CL 

90 88 6 001 630 00 1 630 / Service stand with integrated scissor R 1200 CL 

90 88 6 123 560/561 12 3 560/561 / Spark plug cavity-ignition coil extractor 

90 88 6 234 800/801 23 4 800/801 / Gearbox drain plug hex-head driver insert, length 14 mm 

90 88 6 341 590/591 34 1 590/591 / Rear Caliper Piston resetting device 

Special Tool Catalog on MTAS 

The special tools catalog has been restructured on MTAS. The tools are now 

categorized and accessed via the “On-line Bulletin Search”. 

From the department button on the 

home page or in the Service, Parts, or 

Sales sections of the site, click on 

the “On-line bulletin Search” button. 

Click “Search By Catagories”, then 

select special tool or special tool 

(MoDiTeC) if its an adapter cable used 

for MoDiTeC diagnosis.Then you may 

specifically choose the main group 

and the model for a specific search, 

then press the search documents 

button. 

78 

For R 1200 CL diagnosis 

90 88 6 122 500/501 12 2 500/501 / Primary ignition signal check adapter cable 

90 88 6 127 050 12 7 050 / Secondary ignition signal check adapter cable 

Additional tools for F 650 CS diagnosis 

90 88 6 122 510/511 12 2 510/511 / Primary ignition signal check adapter cable 

90 88 6 122 520/521 12 2 520/521 / Secondary ignition signal check adapter cable 

Additional special tool for F650CS 

90 88 6 271 510/511 27 1 510/511 / Output shaft belt pully holder (used when torqueing nut) 

Special Tools Catalog moved to bulletin search 



New Special Tools - Part of Automatic Initial Tool Shipment 

Auxiliary Stand 90 88 6 001 630 

Base: 90 88 6 001 631 

Jack: 90 88 6 001 633 

Handle: 90 88 6 001 634 

Part of Automatic Tool Shipment 

Coil extractor 90 88 6 123 561 

Used to extract ignition coil from cover. 


Adapter Cable 90 88 6 122 501 

Used to interface ignition coil primary 

circuit with MoDiTeC for diagnosis 



Auxiliary Stand Assembly 

Ignition Coil Extractor 

Check primary ignition wave form with MoDiTeC 

79


New Special Tools 


Used to interface ignition coil secondary 

circuit with MoDiTeC. 


Hex Socket 14mm 90 88 6 234 801 

Remove and install gearbox drain plug 


Caliper Spreader 90 88 6 341 591 

Resets caliper pistons for bleeding and 

pad replacement on rear caliper 


80 

Check secondary ignition wave form with MoDiTeC 

Removal and install of Drain Plug (2) 

R 1200 CL specific rear caliper spreader 


F 650 CS Additional Information 

New Special Tools For F 650 CS 


Used to interface ignition coil primary 

circuit with MoDiTeC for diagnosis. 



Used to interface ignition coil secondary 

circuit with MoDiTeC for diag. 


Pulley Holder 90 88 6 127 511 

Used to hold belt pulley for nut removal 

and torquing when installing new nut. 



Check primary ignition wave form with MoDiTeC 

Check secondary ignition wave form with MoDiTeC 

Checks pulley in place when torquing 

81


82 

F 650 CS Introduction


Wiring & Terminal Designations Electrical Component Designation Legend 

X9380 (SP) Neutral switch 

X9390 (SP) Z1 (Primary coil trigger) 

X9393 (SP) 15E 

X9397 (SP) Diagnostic Connector 

X9401 (SP) 31 Ground 



X9409 (SP) Speedometer 

X9410 Diode (Anode) 

X9411 Diode (Cathode) 



X9428 (SP) Starting system 

X9431 (SP) 30 Fused (F1) Distribution 

X9440 (SP) 30 Distribution 


X9454 (SP) 15 Fused (F1) Distribution 



X9483 (SP) blinker left distribution 

X9484 (SP) blinker right distribution 


X9488 (SP) Brake light distribution 

X9499 (SP) Brake light distribution 

X9500 BMS C Main Connector 

X9506 Ignition Coil 1 

X9507 Ignition Coil 2 

X9540 Hall Sensor 

X9575 Idle Motor 

X9590 Diagnostic connector 

X9592 Idle Motor 

X9601 Fuel Injector I Connector 

X9602 Fuel Injector II Connector 

X9643 (SP) 31 for ground shield 

X9650 (SP) Fuel pump relay power distribution. 

X9690 Oxygen Sensor 

X9803 Load Shed Relay 



X9933 (SP) Heated grips 

X9984 Accessory Socket Connection. 

V 

V9400 Diode/Resistor (Starting Sys.) 

W 

W9690 Oxygen sensor signal ground 

shield 

H9190 ABS indicator lamp 

H9220 Low Fuel Indicator 

H9240 Battery Indicator 

H9340 Rear light 

H9111 Speaker Left 

H9112 Speaker Right 

H9190 ABS and Gen warning Ind. 

H9708 Alarm LED Indicator 

A = Control Units (Processors) 

A9001 Instrument cluster 

A9004 Clock 

A9008 Cruise Control Module 

A9020 Flasher relay module 

A9190 ABS control unit 

A9229 Fuel Level Indicator Dampener 

A9260 A/C Rectifier (Voltage Reg) 

A9500 Motronic control unit 

A9700 Alarm Module 

A9710 Alarm Receiver 

A9910 CD/Radio Electronics 

A9920 Radio Display/Controller 

K = Relays 

K9110 Engine Mang. relay 

K9120 Load Shed relay 

K9123 Hazard flasher relay 

K9125 Turn signal relay 

K9130 Starter relay 

K9168 Low Beam Relay 

K9197 ABS Warning Relay 

K9348 High Beam Relay 

M = Motors 

M9100 Fuel pump 

M9130 Starter 

M9575 Idle Control Motor 

B = Sensors 

B9193 Front ABS sensor 

B9194 Rear ABS sensor 

B9220 Fuel level sensor 

B9540 Hall Sensors 

B9550 Air temp. sensor 

B9561 Oil temp. sensor 

B9690 Oxygen sensor 

B9709 Motion Detector (alarm) 

P = Gauges 

P9002 Rev counter (Tach) 

P9210 Speedometer 

R = Resistors 

R9570 Throttle potentiometer 

R9611 Spark plug 1 

R9612 Spark plug 2 

R9931 Heated grip, left 

R9932 Heated grip, right 

E = Lights 

E9001 Instrument lights 

E9011 Low beam I 

E9012 High beam I 

E9013 Taillight 

E9015 Marker light I 

E9016 Marker light II 

E9016 License plate light 

E9039 Low Beam II 

E9044 High Beam II 

S = Switches 

S9021 Hazard flasher switch 

S9051 Brake switch, hand 

S9052 Brake switch, foot 

S9060 Ignition switch 

S9070 Left comb. switch 

S9071 High beam switch 

S9072 Horn switch 

S9073 Left turn signal switch 

S9074 Headlight flasher 

S9080 Right comb switch 

S9083 Engine Stop Switch 

S9084 Starter switch 

S9091 Clutch switch 

S9092 Neutral safety switch 

S9093 Side stand switch 

S9094 Cruise Control Switch 

S9095 Oil Pressure Switch 

S9120 Radio Control (handlebar 

remote control switch) 

S9930 Heated Grip Switch 

F = Fuse 

F9200 Fuse box I (1-8) 

F9201 Fuse box II (9-16) 

Y = Solenoid valves 

Y9572 Evaporative purge valve 

Y9601 Fuel Injector 

X = Connectors & Solder Points (SP) 

X9001 Instrument Cluster (Processor 

inputs) 

X9010 Headlamp 

X9011 License light (58) 

X9012 License light (30) 

X9013 Rear light (31) 

X9014 Rear light (58) 

X9018 Parking Light 

X9020 Flasher relay 

X9021 Hazard warning switch 

X9028 Instrument Cluster 

(Indicator circuits) 

X9030 Front left turn signal 

X9036 Rear left turn signal 

X9037 Rear left turn signal 

X9040 Front right turn signal 

X9046 Rear right turn signal 

X9047 Rear right turn signal 

X9051 Brake light switch, front 

X9052 Brake light switch, rear 

X9052 Brake light switch, front 

X9054 Brake light switch, rear 

X9060 Ignition Switch 

X9070 Left combination switch 

X9080 Right combination switch 

X9091 Clutch switch 

X9092 Neutral safety switch 

X9093 Side stand switch 

X9095 Oil pressure switch 

X9100 Fuel Pump 

X9123 Hazard flashers 

X9129 Starter relay (86) 




X9136 Starter (30) 

X9157 Horn 

X9190 ABS control unit 

X9193 Front ABS wheel sensor 

X9194 Rear ABS wheel sensor 

X9200 Fuse Box connector 

X9230 Battery positive 

X9231 Battery ground 

X9238 Engine case ground 

X9241 Alternator 

X9334 Hazard flashers 

X9351 Heated grips 

G = Vehicle Power 

G9230 Battery 

G9240 Alternator 

H = Indicators & Output components 

H9002 Neutral Indicator 

H9012 High beam indicator 

H9020 Cruise Control Indicator 

H9030 Front left turn signal 

H9031 Turn signal indicator 

H9035 Rear left turn signal 

H9040 Front right turn signal 

H9045 Rear right turn signal 

H9050 Brake light 

H9095 Oil Pressure indicator 

H9150 Horn 

83/84 

T= Transformer 

T9506 Ignition coil 1 

T9506 Ignition coil 2 



Power Distribution and Grounds - Part 1 of 2 

85/86 



Power Distribution and Grounds - Part 2 of 2 

87/88 



Starter and Alternator 

89/90 



Motronic M2.4 without Anti-Theft System (Part 1 of 2) 

91/92 



Motronic M2.4 with Anti-Theft System (Part 1 of 2) 

93/94 



Motronic M2.4 with or without Anti-Theft System (Part 2 of 2) 

95/96 



Anti Lock Brakes 

97/98 




99/100 



Instrumentation (Part 1 of 2) 

101/102 



Instrumentation (Part 2 of 2) 

103/104 



Lights 

105/106 



Horn, Hazard Flashers & Turn Signal Lights 

107/108 



Radio/CD Player 

109/110 



Heated Grips/Seat & Diagnostic Connector 

111/112 



Alarm System (DWA) 

113/114 



Fuse Designations and Electrical Components View 1 

115/116 



Electrical Components View 2 

117/118 



Electrical Components View 3 

119/120 



Alarm System Components and Programming information 

Overview 

The alarm system is programmed for various function 

choices by using the remote control push buttons after the 

system has been set to programming mode. 

Programmable choices include: 

1. Alarm Tone Type (intermittent or steady) 

2. Arm/Disarm Beeping Tone (on or off) 

3. Automatic immobilization (on or off) 

4. Automatic Alarm Arming (on or off) 

5. Panic alarm feature (on or off) 

Enabling Programming Mode 

• Locate single pin programming connector (X9703) in 

the area of the fuse box. 

• Fabricate a jumper lead long enough to connect the 

programming plug to a suitable ground point. Connect 

jumper lead to programming plug but do not connect 

other end to ground at this point. 

• With the ignition key OFF, press button A on remote to 

Arm system.The directional lights blink twice and the 

alarm will beep twice if it is currently programmed for 

audible beeping tone. 

• Now press button A again to disarm alarm. 

• Immediately connect jumper lead to suitable ground. 

• Press button A again. 

• Immediately switch ignition key ON. A series of three 

unique beep tones will be heard from alarm system, 

this sound signifies the programming mode is active. 

• Disconnect programming lead from battery ground.You 

are now ready to program as outlined on the next 

page. 

NOTE: If the beeps where not heard, you must repeat 

the steps above following the instructions completely. 

121/122 



Alarm System Programming Information 

Programming Procedure 

The alarm system is designed for 12 programmable functions. However, only 5 

functions are currently available (beeping tone, panic alarm, tone type and automatic 

activation of the starter immobilizer and automatic arming of the alarm). 

The other channels are free channels and must be 

skipped by pressing either button A or B during the 

process. 

Follow the chart below and press either button A or 

B to select the function you want active. All channels 

must be programmed in the following 

sequence by pressing either button A or B on the 

remote: 


After the selecting channel 

12, programming is completed 

and indicated by 

three consecutive beeps. 

• 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. 

123



Encoding Replacement RF Remote Controls 

Note:To encode RF Remote Controls 

you will need the 5 digit “personal pin 

code” for the alarm system.The code is 

entered into the system by synchronizing 

the switching of the ignition key 

when the appropriate LED flash corresponds 

with each digit of the code. 

A maximum of four RF remote controls 

can be encoded on the system. 

Activating the encoding function 

1. Use a jumper to connect the programming 

plug to battery 

ground. 

2.Turn the ignition switch to ON, 

after a brief pause switch to OFF. 

3. Wait for the first digit code to 

flash ON and then OFF. Once 

OFF, switch the key back ON. 

4. Pause for approximately 5 seconds 

and switch ignition off. 

Repeat this process for each of 

the remaining digits in the code. 

5. On completion of the last digit, 

three beeps will be heard indicating 

encoding function is 

active. 

NOTE: If the beeps are not heard, 

you must repeat steps 2 - 5 ensuring 

the key is switched ON after the 

last flash of the coded number 

switches OFF. 

Personal Pin Code Card 

Signal the five digit code to the system by switching the ignition key ON when 

the total number of flashes occur for each number in the code. 

Example: Code input for 11559 

124 R 1200 CL Introduction



Encoding the remote controls 

Note: All RF remote controls must be 

encoded at the same time for them to be 

functional 

• Press and hold buttons A and B on the 

remote control simultaneously. 

• LED on remote will flash rapidly, keep 

buttons A and B pressed down. 

• After approximately 10 seconds, the 

remote LED will stop flashing, release 

buttons A and B. 

• 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 successful. 

• Repeat the procedure for all other remote controls. 


RF Remote LED 

Encoding RF Remote Control 

125

R 1200 CL

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