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1994 – 2004 BMW Motorcycle History

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Filed Under (BMW) by admin on 17-11-2010

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1994 brought many changes to BMW, most obviously by the introduction of the “R259″ series twins and the elimination of the old standby “Airhead” twins that had been BMW’s trademark for seven decades. While it is interesting to look at all the technologies introduced during the 1994 to 2004 time block, it is also exciting to look into what was going on as far as changes in BMW more esoteric than measurable. In this author’s opinion there were unspoken changes in BMW’s mindset and philosophy. BMW had forged it’s reputation for long lasting, simple machines built to the highest standards and quality; aimed at a dwindling, older (OK, Jeff, more mature) market of enthusiastic but eccentric riders. They built motorcycles that were easy for the owners to maintain and modify to fit their specific wants. BMW had always built their bikes their way; often it seemed like they did so in spite of what the younger and upwardly mobile riders were looking for. By 1994, the airhead was simply not a sellable motorcycle; the buying market was younger and wanted performance in line with what the Japanese products offered at much lower prices. The K 75/100 series that were so far ahead of their time in 1984 when they were introduced were also showing their age. No doubt, BMW knew this was coming many years before the new “Oil Head” was introduced. They knew that the riding community had reduced its mean age substantially. The younger riders had money to spend on a bike that had to be BMW, yet had to be totally more modern both in performance and in perception than what BMW had been selling. Thus, the R259 was born. The Birth of the R259 Twins The new BMW corporate mindset, if you will, was no longer concerned with selling motorcycles that would be handed down from one generation to the next, nor was BMW concerned about ease of maintenance with standard hand tools. Although the new bikes were still able to outlast the riders, the concern for building units to last a quarter-million miles was not so much in the forefront of the design. The new models would have to be powerful, fast, handle better than anything on the road; they would need to offer a standard of technology that the Japanese would never build. They should be complex pieces of rolling art. Most obvious, though, was that they would build a product aimed at an entirely new market of riders who would likely not be interested in maintaining the bikes themselves or really understanding the nuances of design. The new customers BMW was looking for were serious riders who were more interested in the fun and excitement of riding than they were in savoring the history of the older designs

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GL1800 Goldwing Trike Conversion Kit Installation Instructions

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Filed Under (Honda) by admin on 10-11-2010

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Disassembly of motorcycle: 1. Place the motorcycle on the center stand or lift. 2. Set the shock preload to zero. 3. Remove the four m8 x 1.25 SHCS from the passenger handles and remove seat. 4. Remove the rear side covers. 5. Disconnect negative battery terminal. 6. Remove the four m8 x 1.25 SHCS and the passenger floorboards. 7. Remove the six m5 x 0.80 BHCS and the foot rest under cover. 8. Remove the six m5 x .80 BHCS and the swing arm pivot bolt covers. 9. Remove the four m8 x 1.25 flange bolts on the rear crash guards. Remove and discard the rear crash guards and bolts. 10. Remove the four #2 Phillips head screws from the inside of the trunk to remove the trim pieces on the sides. 11. Remove the two #2 Phillips head screws in the rear trim molding and remove molding. 12. Remove the seven #2 Phillips head screws from the lower trunk cover. Remove the lower trunk cover. 13. Remove the five #2 Phillips head screws from the trunk opener cover. Remove the trunk opener cover. 14. Disconnect the left and right saddlebag release cables. 15. Remove the five m6 x 1.0 BHCS in the rear fender panel. Remove and discard the rear fender panel and cap screws. 16. Disconnect the trunk wiring. 17. Remove the four m6 x 1.0 flange screws. Remove the trunk from the saddlebag / trunk stay. 7 18. 2005 and older 2005 and older 2005 and older 2005 and older ABS equipped motorcycles: ABS equipped motorcycles: ABS equipped motorcycles: ABS equipped motorcycles: Remove rubber bungee from ABS Control Unit, and save for reinstallation. 19. Remove the two side cover grommets from each saddlebag. ( 4 grommets total ) 20. Remove the left and right hand saddlebag latches, strikers, and release cables for core parts return. Refer to Honda service manual. 21. Remove the left and right saddlebag taillights and sub- harnesses for core parts return . Refer to Honda service manual. 22. Remove the four m6 x 1.0 flange bolts from each saddlebag. Remove and discard the saddlebags. 23. Remove the six m6 x 1.0 flange bolts from the exhaust tips. Slide the tip off the muffler body. Save tips and bolts for reinstallation. 24. Loosen the four m8 x 1.25 SHCS on the muffler clamps. Remove the two m8 x 1.25 flange bolts. Remove and discard the mufflers and muffler gaskets. 25. Remove the four m6 x 1.0 BHCS, two rubber washers, and front fender A. 26. Remove the four m5 x .80 BHCS and chrome front fender covers. 27. 2006 & UP. 2006 & UP. 2006 & UP. 2006 & UP. Remove the Remove the Remove the Remove the two m6 x two m6 x two m6 x two m6 x 1.0 flange bolts on 1.0 flange bolts on 1.0 flange bolts on 1.0 flange bolts on rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. rear of saddlebag/trunk stay. 28. Unplug connector and remove amp and save for Unplug connector and remove amp and save for Unplug connector and remove amp and save for Unplug connector and remove amp and save for reinstallation. reinstallation. reinstallation. reinstallation. 29. Cut lower saddlebag supports off the saddlebag/trunk stay, where the round tubing meets the square, and cut the gusset flush, removing any burrs. See Figure 1. 30. Remove trunk stay for later use. 31. Remove the two m5 x .80 nuts on the license plate light. Remove and discard the license plate ligh

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Integral ABS and ASC – new Riding Dynamic Control Systems for BMW Motorcycles

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Filed Under (BMW) by admin on 16-11-2010

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Entering its next generation, BMW Motorrad Integral ABS is taking a quantum leap in the process of evolution, advancing from a stand-alone solution acting only on the brakes into a fully networked all-round system. Offering the new generation of Integral ABS, BMW Motorrad provides the foundation for additional dynamic riding control systems with a reduction in technical requirements and features. And following the customer’s wishes, this new generation also opens up the option in future for further-reaching rider assistance functions. The first step in this direction is BMW Motorrad ASC Automatic Stability Control available as of 2007. This system serving to control drive spin on a production motorcycles is being introduced as an optional extra on the touring models in the BMW K and Boxer Series. Once again, therefore, BMW is acting as the pioneer in the introduction of advanced safety technologies on the motorcycle. This further enhances the leadership which BMW Motorrad has shown in the area of active safety for more than 15 years. Choosing the right development partner for both systems, BMW Motorrad obviously had to focus on that partner’s specific competence in control technology and the networking of functions within the vehicle. In recent years, major car suppliers have become aware of the technical challenges presented by the motorcycle with its specific riding dynamics and the growing potential for motorcycle control systems in the market. The decisive point in preselection of the development partner was the willingness and ability to develop specialised solutions suitable for use on BMW motorcycles. So taking this into account, joint development of the new generation of ABS brake technology started together with Continental-Teves in early 2003. Integral ABS. BMW Motorrad’s new Integral ABS technology has been developed separately from the previous system and the entire layout of the system has been newly conceived from the ground up. Capitalising on progress in technology in both hydraulics and electronics, the development engineers have succeeded in simplifying the architecture of the system while at the same time enhancing its functions to an even higher standard. The result is supreme stopping power and very short stopping distances even without electrical power assistance on the brakes.

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BMW K1200LT Motorcycle Brake Light Flasher Installation

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Filed Under (BMW) by admin on 26-10-2010

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1. Use the T-20 Torx wrench to remove the plastic cover (5 screws—see Figure 2) to the compartment beneath the mirror inside the trunk. Figure 2. Remove 5 screws to remove plastic cover 2. Remove the wire from underneath the plastic holder and separate the two halves of the connector going to the brake light. 3. Cut off both BMW connectors (close to the connector) and strip about ¼” of insulation off the ends of the wires. Twist the loose strands of wire together. To make it a little easier to attach the connectors, you can cut carefully back the black insulation around the wires coming from through the rubber grommet. 4. On the wires going through the rubber grommet in the trunk to the brake light, crimp a red female bullet connector to the purple (ground) wire and a red male bullet connector to the orange (hot) wire. 5. On the remaining wires, crimp a red male bullet connector to the brown (ground) wire and red female bullet connector to the gray/yellow (hot) wire (see Figure 3).

BMW K1200 LT Chrome Trunk Rack INSTALLATION AND OWNER'S MANUAL

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Filed Under (BMW) by admin on 26-10-2010

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1. Place the motorcycle securely on its center stand or work stand. 2. Remove any trunk rack already installed. Set aside. 3. For predrilled trunk lids, enlarge the drill holes as indicated in the Note above. 4. For lids that are not drilled locate the Drill Template (form No.10-117726-000) and carefully follow the drilling Instructions that follow. Do not attempt to drill the holes without a Drill Template. DRILLING INSTRUCTIONS TO USE ALONG WITH THE DRILL TEMPLATE 1. Cut out large template along solid bold line. 2. Line up the template front and adjacent sides and tape in positions marked (1) 3. Smooth the template and tape positions marked. (2) 4. Crease template bottom “V” with fingernail along dashed line. 5. Smooth the template and tape position marked. (3) 6. Smooth the template and tape positions marked. (4) 7. Cut out measurement template. 8. With measurement template pulled taught check hole positions diagonally. 9. If necessary lift tape positions marked (4) and reposition holes H3 and or H4 until diagonal measurement is correct. 10 . Drill 1/8″ or 3mm pilot hole normal to the surface (as illustrated on the template) at the positions shown. 11 . Open the pilot hole to 5/8″ or 16mm with a hole saw

Suspension Basics for BMW Motorcycles

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Filed Under (BMW) by admin on 30-11-2010

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tires: Tires are the first part of any suspension system. The design of the tire and even the pressure you run can have a profound affect on the way your motorcycle handles. Stiff, low profile tires will give a sharper feel to the bike, as will higher tire pressures. Those of us who ride our GS’s off the road will decrease the tire pressure to about 50% of the street spec when we are in the dirt. The tire then becomes a very active part of the suspension, but will wallow like an old pig if not re-inflated when pressed back into pavement duty. It still surprises me when we have a customer complain that his BMW needs new shocks when they come in with nearly flat tires. It is possible that the best dollars-per- unit improvement you can make to your BMW may be in keeping the tires inflated. Chassis: There is not much that we can do about the chassis design, unless we are Troy the Welder, but it is a fact that different frames and swing arms flex differently and therefore are part of the suspension. On the Airheads, we often braced various parts of the frame and swing arms, resulting in improved handling that even mere mortals could appreciate. On the latest BMW’s it would take the likes of a Valentino Rossi to even notice if the parts were stiffened. Stiffer is not always better. One of the Japanese racing bike manufactures controls the stiffness of the frame in various areas to allow some flex for better handling. So, Mr. Rossi might not even like it if Troy stiffened his new BMW. Springs: Springs control the ride height of the motorcycle and the ability to allow for different loads. On most BMW’s there is a way to adjust the spring preload to some extent so that the ride can be optimized for a light rider or two-up operation with luggage. Dampers: Dampers control the speed and frequency at which the suspension operates by changing the kinetic (moving) energy to thermal (heat) energy. Without the damper, the suspension would oscillate as each movement occurred, resulting in decreased vehicle control. Dampers on BMW’s fall into two main groups. On airheads, older K bikes, F and G models, and the R1200 HP-2, the front dampers are integrated into the forks. On the rear of the above mentioned -3 – models, and on both ends of all the rest of the bikes, there is a more common shock absorber, around which the spring is located. The HP-2 uses an air spring and air dampened rear shock. Seat: OK, folks, this is here for my old buddy Jeff. We know that a seat isn’t part of suspension, but a bad one sure can make you miserable. We have sent dozens of seats to our friend Mike Harris for inexpensive mods that might improve your riding enjoyment more than any suspension changes you could make! Let us know if we can help you with this most important item

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BMW R 1200 C And R 850 C REPAIR MANUAL

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Filed Under (BMW) by admin on 22-11-2010

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BMW Inspection 1000 km/600 miles I -BMW Service II -BMW Inspection III -BMW Annual Service IV Reading out MoDiTeC fault memory (Inspections I, II, III and IV) • Remove the left air cleaner trim panel. • Connect MoDiTeC to diagnostic plug. • Read out the fault memory. • Perform any repair work indicated. Checking throttle cable play, adjusting if necessary (Inspections I and III) • Check throttle cable for free movement and freedom from abrasion or kinking; renew if neces- sary. • With the steering turned to various angles, open the throttle twistgrip fully and allow it to close again. • When released, the twistgrip must return to the closed position by itself. • Pull back the protective cap. • Preset throttle cable play with the engine cold to 1.5 mm (0.06 in). • Warm the engine up to its regular operating tem- perature. • Adjust throttle cable play to 0.5mm (0.02 in) Changing engine oil, renew oil filter element (Inspections I, II, III and IV) L Note: If the motorcycle is ridden only for short distances or outside temperatures are below 0°C (32°F): change the oil and renew the oil filter element every 3 months, but at least every 3 000 km (1 800 miles). • Change the oil while it is at regular operating temperature. • Remove screw plug. • Unscrew oil drain plug and drain off oil. • Fit new seal and screw in drain plug. • Use oil filter wrench, BMW No. 11 4 650 , to unscrew and remove the oil filter. • Coat sealing ring on new oil filter element with oil and screw in. • Add oil. • Insert and tighten the screw plug. • Check engine oil level with the motorcycle in a horizontal position; use the auxiliary stand, BMW No. 001550 . e Caution: Never add engine oil above the MAX mark. X Tightening torque: Oil filter………………………………………………… 11 Nm Oil drain plug………………………………………… 32 Nm Fill quantity for engine: With oil filter change.. 3.75 l (6.6 Imp. pints/3.96 US quarts) Without oil filter change.. 3.50 l (6.2 Imp. pints/3.69 US quarts) Oil volume between MIN and MAX marks……0.50 l (0.88 Imp. pint/0.52 US quart) Engine oil grade: Brand-name HD oil for four-stroke spark-ignition engine, API classifications SE, SF, SG; combination with CC or CD specification

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1999-2005 BMW K1200LT Motorcycle Signal Mirror Installation Instructions

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Filed Under (BMW) by admin on 26-10-2010

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1. Start on either the left or right side mirror. These instructions start with the right side mirror. Remove the factory mirror by inserting the pry bar as shown. Slowly twist the pry bar to disengage the mirror. NOTE: Insert the pry bar as close to the mirror mount as possible before prying out the OE mirror. Not doing so may cause the crossbar on the motor actuator to break. 2. Grab the mirror housing as shown and slowly push down to disengage housing from motorcycle. 3. Once you have the mirror housing removed, route the Signal® mirror wire harness through the hole in the housing. Note: Leave about 6″ of slack, on the wire, for adjustment later on. 4. Use a screwdriver and remove the screw from the front turn indicator lens. 5. Disengage the lens and remove the light bulb as shown. 6. Route the Signal® mirror wire harness through the top opening in (A) and out the bottom opening in (B).

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2001-2004 HONDA GL1800/A Trunk Opener Unit Removal/ Installation instructions

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Filed Under (Honda) by admin on 29-01-2011

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come customers may experience trunk or saddlebag lids not opening when the corresponding latch lever is pulled. To correct this condition, the opener mechanism must be replaced with a new opener mechanism. Follow the Trunk Opener Unit Removal/Installation instructions in the GL1800/A Gold Wing Service Manual. Opener Unit P/N: 81310-MCA-A22 H/C: 7700768 The normal GL1800/A warranty applies. Follow all normal warranty procedures and guidelines. Labor Operation: 412122 Flat Rate Time: 0.6 If you feel that goodwill consideration is appropriate, contact your District Service Manager or TechLine BEFORE starting this repair. 2001-2004 GL1800/A Trunk Opener Unit MTB 10535 (0403) GL1800/A #15 MAY 2004 REPAIR PROCEDURE PARTS INFORMATION WARRANTY INFORMATION QUESTIONS PART DESCRIPTION TRUNK OPENER UNIT

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BMW Motorcycle F 650 GS/ F 800 GS Accessories

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Filed Under (BMW) by admin on 20-11-2010

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Stowage-equipment line Vario case, black, left 71 60 7 696 299 £184 / G Vario case, black, right 71 60 7 696 300 £185 / G (+) Case carrier for Vario case, including fasteners 71 60 7 696 301 £144 / G (+) Lock barrel, complete, for 2 cases 51 25 7 688 566 £20.80 / I (o) Lock barrel by code for vehicle and/or case matching locks (order 2x) 51 25 7 681 199 £33.59 (o) Lock-barrel set 51 25 7 698 202 £15.20 / I Liner for Vario case, left 71 60 7 687 610 £67 / I Liner for Vario case, right, and Vario topcase 71 60 7 687 611 £67 / I Vario topcase, black 71 60 7 696 302 £225 / I (+) Luggage rack, large, for Vario topcase (including adapter plate) 71 60 7 696 303 £64 / I (+) Lock barrel for topcase 51 25 7 688 568 £12.50 / I (o) Lock barrel by code for vehicle and/or case matching locks (order 1x) 51 25 7 681 199 £33.60 / I (o) Lock barrels for 2 cases and topcase 51 25 7 688 567 £29.10 / I Liner for Vario case, right, and Vario topcase 71 60 7 687 611 £67 / I Backrest pad for topcase 71 60 7 688 877 £45 / I Luggage carrier, small 71 60 7 701 810 £42.90 / G Tank rucksack, waterproof 71 60 7 711 240 £130 / I Enduro rear softbag 71 60 7 711 245 £35.90 / I Sport softbag, small, 19 l 71 60 7 694 117 £102 / I Sport softbag, large, 51 l 71 60 7 693 567 £139 / I Stuffbag, waterproof, 53 l 72 60 7 653 818 £90 / I Luggage strap with pull-tight buckle 72 60 2 304 808 £6.30 / E Bungee-cord spider 72 60 9 057 579 £3.95 / E Design line Spray-guard extension, rear 71 60 7 695 031 £24.20 / I Sound components Akrapović sports silencer 71 60 7 713 339 *1 £475 / G Ergonomics and comfort line Windscreen, large, tinted 71 60 7 713 834 *1 £138 / I Windscreen, large, clear (standard for F 800 GS) 71 60 7 713 833 £127 / I Windscreen, small, clear (standard for F 650 GS) 71 60 7 713 296 £87 / I Centre stand (F 650 GS) 46 52 7 700 864 *2 £83 / I Centre stand (F 800 GS) 46 52 7 700 049 *2 £91.50 / I (+) Fasteners for centre stand (F 650 GS + F 800 GS) 71 60 7 706 738 £24.90 / I Seat, low, black, 790 mm (F 650 GS), 850 mm ( F 800 GS) 52 53 7 695 013 £174 / I Heated handlebar grips and switches (see electronic parts catalogue) Navigation and communication components BMW Motorrad Navigator III plus 2008 72 60 7 716 116 *1 £650 / I (+) Holder for BMW Motorrad Navigator 71 60 7 697 785 £45.80 / E (+) Securing screw (order 4 of) 32 71 7 652 161 £4.55 / I Connecting cable for BMW Motorrad Navigator 71 60 7 686 670 £55 / E TMC module for BMW Motorrad Navigator 72 60 7 702 687 *1/3 £111 / E Car kit for BMW Motorrad Navigator 72 60 7 703 996 *3 £60.50 / E Navigator carry-bag function 71 60 7 683 161 £49 / I Safety line Hand-protector bar 71 60 7 716 043 £57 / I (+) Countersunk-head screw (order 2 of) 32 71 7 712 836 £3.34 / E Hand protector, small 71 60 7 705 963 £19.50 / I Hand protector, large 71 60 7 715 135 £23.10 / I Protector-mounted spoiler for hand protector, large 71 60 7 705 964 £15.20 / I Crash bar, left 71 60 7 699 437 £104 / I Crash bar, right 71 60 7 699 438 £104 / I (+) Fasteners for crash bar 71 60 7 702 395

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