BMW R 1200 CL Manuel utilisateur

Motorcycles

Technical

Training

BMW Motorcycles

Motorcycle Training

J:\BULLETIN\SERVICE\MCTRAINI\Manuals\R1200CL-PDI.qxd

R 1200 CL

• Technical Features in Detail

• Uncrating & Set up

• Pre Delivery Inspection

• Inspection Procedures (600 Mile)

• Special Tools

• Wiring Diagrams

09/02

BMW of North America, LLC

BMW Motorcycles

ZU-X-S-51

R 1200 CL

Disclaimer

R 1200 CL Introduction

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.

R 1200 CL

Table of Contents

R 1200 CL Introduction

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

Technical Features in Detail

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

uncrating, set up, PDI and maintenance

information. However, allways refer to tech-

nical 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.

Pearl Silver Metallic

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 suitabili-

ty and a powerful appearance.

In addition to the Pearl Silver Metallic shown

on the previous page, color choices at time

of introduction also include:

Equipment Levels. There are two ver-

sions; 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 equip-

ment 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 avail-

able 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 body-

work 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 han-

dlebars 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.

R 1200 CL

Introduction

Technical Features in Detail

Capri Blue Metallic

Mojave Brown Metallic

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 succes-

sion; lubricating oil and cooling oil are sep-

arated.

Engine management is controlled by the

Motronic MA 2.4. in conjunction with the per-

formance-determining components, such s

camshafts, valve sizes, air intake design, the R

1200 CL engine is also designed in such a

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.

R 1200 CL

Engine

Technical Features in Detail

The two piece light alloy crankcase is man-

ufactured using a pressure die-casting

method.The oil pan, which holds 3.75 litres,

is integrated into the engine case halves.

As with all R Series bikes, the engine and

gearbox is a combined load bearing ele-

ment of the chassis. 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 accommo-

dated 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 cylin-

der 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 tap-

pets, short aluminum tappet push rods and

forged valve lifters.

R 1200 CL

Engine

Technical Features in Detail

Engine Components

Crankshaft / Pistons

Cylinder head / Valve train

R 1200 CL

Engine

The engine is designed to run on premium

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

ture 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 sec-

ondary spark plug wire ensuring consistent

spark voltage over the lifetime of the motor-

cycle. 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 sec-

tions: two exhaust manifolds consisting of a

55 mm double walled tube and a flange-

mounted, 1-section exhaust silencer with

short tail pipes. This has 4 chambers and is

based on the reflection and absorption prin-

ciple.

In the exhaust silencer of the R 1200 CL, two

catalytic converters are used. The small

diameter and a flat design, offers a higher

sectional flow. The cylindrical catalytic con-

verter 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 man-

ifolds 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 stoi-

chiometric mixture (lambda=1).

The catalytic converters are made of palla-

dium and rhodium. Palladium accelerates

the oxidation of hydrocarbons and carbon

monoxide. Rhodium reduces nitric oxide.

New Ignition Coils

Exhaust Components

Twin Catalytic Converters, Single O2Sensor

R 1200 CL Introduction

R 1200 CL

Clutch

Centrifugal mass is of advantage for Cruiser

engine speeds. This is achieved by a solid

clutch case cover with the R 1200 CL.

The weight of the clutch disc on the other

hand, with a diameter of only 165 mm, has

been reduced in order to attain a fast stand-

still of the gear drive shaft.

This optimizes the engaging and disengag-

ing of the 6-speed gearbox.The wear resis-

tant friction lining of the clutch disc togeth-

er with the strong casing cover additionally

offers high temperature resistance.

Clutch Components

R 1200 CL Introduction

The R 1200 CL is equipped with a new six

speed Getrag gearbox exhibiting the gear-

box 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

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 provid-

ing pleasant touring with lower fuel con-

sumption on interstate journeys.

In the light alloy casing, three gear shafts

are installed in wear-resistant clean-bearing

deep groove ball bearings.

R 1200 CL

Gearbox

Technical Features in Detail

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