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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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BMW Heated Seat Wiring Instructions

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Filed Under (BMW) by admin on 28-10-2010

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1. Locate the battery. 2. Find an appropriate and convenient mounting location for the controller. NOTE: The heat controller has adhesive Velcro on the back for mounting on a flat surface. 3. Connect the components per the wiring diagram. Route and secure wires with electrical friction tape and/or wire ties. In this system, the relay control wire is designed to be connected/spliced to a IMPORTANT: “switched”wire such as a tail light, head light, etc. NOTE: For CANbussystembikes (see above), you MUST spliceor connect to anon-board accessory jack circuit. S T EA RELAY BATTERY 10 AMPFUSE HEAT CONTROLLER SPLICE INTO SWITCHED LINE (I.E. TAIL LIGHT OR ACC. JACK HOT LEAD) WIRING DIAGRAM SARGENT CYCLE PRODUCTS Chilliis a registered trademark of Calamander ltd. * BATTERY SIDE OF POWER CONNECTOR INDICATED WITH RED WRAPPING * IMPORTANT! Caution: Sargent’s limited warranty does not extend to any products damaged as a result of accident, misuse, abuse, normal wear and tear, acts of God or other circumstances beyond Sargent’s control, including loss or damage in transit by carrier, or as a result of service or modification by anyone other than Sargent.

BMW R1100RT, BMW R1150RT Signal Mirror Installation Instructions

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

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1. These instructions start with the right side mirror. Grab the mirror housing as shown and slowly push down to disengage housing from motorcycle. 2. Once you have the mirror housing removed partially, twist and remove the light bulb from mirror housing. Remove mirror housing and set it on a cloth covered surface. 3. Remove the factory mirror by inserting a slotted screwdriver against each mirror mount snaps. Slowly twist and pry each snap until it releases from motor actuator. Repeat process until factory mirror disengages. NOTE: Insert the slotted screwdriver as close to each of the snaps as possible before prying out the OE mirror. Not doing so may cause the crossbar on the motor actuator to break. Connect the two mating connectors from the adapter Signal® mirror wire harness and the new Signal® mirror wire harness. Cut a slot in the foam disc to accommodate the anti-vibration prongs on the motor adapter. Place the foam disc onto the center of the Signal® mirror motor interface. Connect the Signal® mirror mating connector to the Signal® mirror wire harness. 5. Remove Cap Sheet from two-sided adhesive disc on back of Signal ® mirror. Align the anti-rotation prongs found on the top and bottom or left and right with the corresponding slots on the motor mount. Use the palm of your hand, push down on the Signal® mirror and the mirror housing until the Signal® mirror motor mount is fully engaged. Note: Push firmly on all sides of the Signal® mirror to ensure proper engagement and travel. Not doing so could result in mirror falling off. 6. Locate the light bulb and carefully disconnect the original light blue with black stripe wire [hot wire]. Connect the red wire from the Signal® mirror wire harness to the spade terminal on the light bulb. Connect the original light blue with black stripe wire to the other spade terminal located on the red wire of the Signal® mirror wire harness. Repeat the process for the original brown wire and the black wire from the Signal® mirror wire harness [ground wires]. Insert the light bulb back into the mirror housing. 7. Align the 3-pins with their corresponding snap holes and snap the mirror housing into place. 8. Insert key into the ignition and turn to the “ON” position. Activate the right hand turn indicator to verify that the new Signal® mirror is working correctly. Replace any other accessories necess

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HARLEY DAVIDSON SECURITY SYSTEM SMART SIREN KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 09-02-2011

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REMOVAL 1. Refer to the owner’s manual and follow the instructions to disarm the security system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. For All Models except 2002-2003 Touring and 2003- Later Softail: Refer to the owner’s manual and follow the instructions to disconnect the battery, negative (-) cable first or remove the main fuse. For 2002-2003 Touring and 2003-Later Softail Models: Remove seat following the instructions in the service manual and disconnect the battery, negative (-) cable first. Save seat hardware for installation. INSTALLATION 2002-2006 VRSCA, VRSCB, VRSCD Models 1. Open the seat. 2. See Figure 1. Remove the splash guard (mud flap) nuts. 3. See Figure 2. Lower the mud flap from the installed position and allow it to rest on the rear tire 3. Slide the siren into place on the left side of the electrical caddy so the sounder disc (6) faces out. 4. Refer to the owner’s manual and follow the instructions to install the main fuse. 5. Align the barbed studs on the side cover with the grommets in the frame and push side cover firmly into place. 6. Install the left side saddlebag per the instructions in the owner’s manual. 2003 and later Softail Models EXCEPT FXCW/C 1. Remove the right side saddlebag (if equipped) per the instructions in the owner’s manual. NOTE The siren connector is installed on an electrical panel under the rear fender on all Softail models. The rear of the motorcycle may have to be raised slightly to allow removal of the splash guard. 2. Remove the two bolts at the bottom of the splash guard. Bend the upper right corner of the splash guard toward the rear tire and lift upward to unhook the splash guard from the tab on the rear fork. Remove the guard from beneath the fender. 2 1 3 is01316 1. Siren mounting area 2. Siren connector [142B] 3. Harness clip Figure 16. Siren Connector (Softail Models EXCEPT FXCW/C) (Rear Fender View with Rear Wheel Removed) 3. See Figure 16. Remove the siren connector [142B] (2) from the receptacle in the siren mounting area (1) of the electrical panel. 4. See Figure 17. Insert security siren (1) connector [142B] into the siren box receptacle until the connector latches securely. 5. Orient the siren (1) as shown, with the harness connector (2) toward the bottom and the sounder disc (5) facing out. Carefully snap the siren into the electrical panel. 6. Insert the siren harness lead (4) into the harness clip (3) to keep the harness clear of other components. 7. If necessary, secure the connector wiring to the electrical panel wiring with a cable strap (not provided). 8. Hook the slot at the top of the splash guard over the tab on the rear fork and install the guard with the two screws removed earlier. Tighten securely. 9. Install the right side saddlebag (if equipped) per the instructions in the owner’s manual. 10. Refer to the owner’s manual and follow the instructions given to connect the battery cables or install the main fuse

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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 R259 Installation Instructions Fuel Control For BMWOilheads

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Filed Under (BMW) by admin on 12-11-2010

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Installation R1200 C -Removethechrome right air filter cover. Release the brake fluid reservoir from its mount. Follow the oxygen sensor lead from the exhaust to the connector. It is mounted to the back of the brake fluid reservoir mounting bracket with cable ties. Cut the cable ties to release the connector from the bracket. Gently pull the connector apart. Insert the male O2 connector from the R259 into the oxygen sensor lead. Connect the female side of the R259sO2 connector to the bike’swiringharness side. Make sure both sets of connectors are fully seated. Cable tie the sensor lead connector back to the bracket and tuck the other O2 connector under the front of theairhorn. -Depressthe retaining bail on the right fuel injector connector and gently pull off the connector. Install this connector on the male R259 injector lead. Install the remaining R259 connector on the right injector. -Connecttheground lead by removing the allen screw (5mmhex) that secures theairboxtothe frame. Place the screw through the lug on the ground lead and reinstall and tighten the screw. Go to section 3 and verify power-up. Tuck the wiring below and behind theairhornand cable tie as necessary. Using the supplied velcro, attach the controller box to the top of theairhorn. Reinstall the brake fluid reservoir in its mount and reinstall the side-cover. Seethe Techlusionwebsite for more detail. Installation R850, R1100, R1150, R1100S -Refertothe appropriate BMW service guides and remove the fuel tank. On some models it maybe possible to have an assistant lift the tank up and to the left to expose the oxygen sensor connector, without fully disconnecting the tank. Locate the oxygen sensor connector by following the lead from the exhaust system. It will be cable tied to the right frame backbone. Cut the retaining cable ties and pull the connector away from the frame. Open the connector and insert the male R259 O2 connector into the oxygen sensor lead, and the female to the bike’swiringharness. Cable tie these back to the right frame backbone. -Routethe R259 wiring harness down the right frame, in-between the battery tray and the rear fuel tank mount. Using the supplied velcro attach the R259 to theairboxlid. Locate the lead on the right fuel injector, and while depressing the locking bail on the connector, gently pull the leadoff. Install this lead on the R259 male injector connector; install the remaining connector on R259 harness to the right injector. Make sure all of the connectors are fully seated. Cable tie any excess wiring away from the fuel lines and throttle mechanism. -Connecttheground lead to the battery negative terminal or an alternate good ground. -Re-install the fuel tank. Make sure the fuel lines are connected and their routing is correct. Insure that both throttle cables are correctly seated in their adjusters on the throttle bodies, and that nothing interferes with the throttle mechanisms on either throttle body. Turn the key on and allow the fuel system to pressurize. CHECK FOR ANY FUEL LEAKS and repair as necessary. Go to section 3 to verify power-up. Re-install any other bodywork removed. Seethe Techlusionwebsite for more detail.

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Installation Instructions Fuel Control For BMW Oil heads

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

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Removethechrome right air filter cover. Release the brake fluid reservoir from its mount. Follow the oxygen sensor lead from the exhaust to the connector. It is mounted to the back of the brake fluid reservoir mounting bracket with cable ties. Cut the cable ties to release the connector from the bracket. Gently pull the connector apart. Insert the male O2 connector from the R259 into the oxygen sensor lead. Connect the female side of the R259sO2 connector to the bike’swiringharness side. Make sure both sets of connectors are fully seated. Cable tie the sensor lead connector back to the bracket and tuck the other O2 connector under the front of theairhorn. -Depressthe retaining bail on the right fuel injector connector and gently pull off the connector. Install this connector on the male R259 injector lead. Install the remaining R259 connector on the right injector. -Connecttheground lead by removing the allen screw (5mmhex) that secures theairboxtothe frame. Place the screw through the lug on the ground lead and reinstall and tighten the screw. Go to section 3 and verify power-up. Tuck the wiring below and behind theairhornand cable tie as necessary. Using the supplied velcro, attach the controller box to the top of theairhorn. Reinstall the brake fluid reservoir in its mount and reinstall the side-cover. Seethe Techlusionwebsite for more detail. Installation R850, R1100, R1150, R1100S -Refertothe appropriate BMW service guides and remove the fuel tank. On some models it maybe possible to have an assistant lift the tank up and to the left to expose the oxygen sensor connector, without fully disconnecting the tank. Locate the oxygen sensor connector by following the lead from the exhaust system. It will be cable tied to the right frame backbone. Cut the retaining cable ties and pull the connector away from the frame. Open the connector and insert the male R259 O2 connector into the oxygen sensor lead, and the female to the bike’swiringharness. Cable tie these back to the right frame backbone. -Routethe R259 wiring harness down the right frame, in-between the battery tray and the rear fuel tank mount. Using the supplied velcro attach the R259 to theairboxlid. Locate the lead on the right fuel injector, and while depressing the locking bail on the connector, gently pull the leadoff. Install this lead on the R259 male injector connector; install the remaining connector on R259 harness to the right injector. Make sure all of the connectors are fully seated. Cable tie any excess wiring away from the fuel lines and throttle mechanism. -Connecttheground lead to the battery negative terminal or an alternate good ground

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SUZUKI SV 1000 RADIATOR (COOLING SYSTEM) SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION CODE DETECTED ITEM DETECTED FAILURE CONDITION CHECK FOR COO NO FAULT C11 Camshaft position sen- sor The signal does not reach ECM for more than 3 sec . after receiving the starter signal . The camshaft position sensor wiring and mechanical parts (Camshaft position sensor, intake cam pin, wiring/coupler con- nection) C12 Crankshaft position sensor The signal does not reach ECM for more than 2 sec . after receiving the starter signal . The crankshaft position sensor wiring and mechanical parts (Crankshaft position sensor, wiring/coupler connection) C13 Intake air pressure sensor The sensor should produce following voltage . (0.50 V < sensor voltage < 4 .85 V) Without the above range, C13 is indicated. Intake air pressure sensor, wiring/coupler connection C14 Throttle position sen- sor The sensor should produce following voltage . (0.20 V < sensor voltage < 4 .80 V) Without the above range, C14 is indicated. Throttle position sensor, wiring/coupler connection C15 Engine coolant temperature sensor The sensor voltage should be the following. (0.15 V <_ sensor voltage < 4 .5 V) Without the above range, C15 is indicated. Engine coolant temperature sensor, wiring/coupler connection C21 Intake air temperature sensor The sensor voltage should be the following. (0.15 V < sensor voltage < 4 .5 V) Without the above range, C21 is indicated. Intake air temperature sensor, wiring/coupler connection C22 Atmospheric pressure sensor The sensor voltage should be the following. (0.50 V < sensor voltage < 4 .5 V) Without the above range, C22 is indicated. Atm. pressure sensor, wiring/coupler connection C23 Tip over sensor The sensor voltage should be the following for more than 2 sec . after ignition switch turns ON . (0 .20 V < sensor voltage < 4 .80 V) Without the above value, C23 is indicated. Tip over sensor, wiring/coupler connection C24 or C25 Ignition signalCrankshaft position sensor signal is produced and ECM determines the ignition signal but signal from ignition coil is interrupted continuous by 4 times or more. In this case, the code C24 or C25 is indicated. Ignition coil, wiring/coupler connection, power supply from the battery SERVICING INFORMATION 8 .3 C28 Secondary throttle valve actuator No operating voltage is supplied from the ECM, C28 is indicated. STVA can not operate. STVA lead wire/coupler, STVA C29 Secondary throttle valve position sensor The sensor should produce following voltage . (0.10 V < sensor voltage < 4 .90 V) Without the above range, C29 is indicated . Secondary throttle position sensor, wiring/coupler connection C31 Gear position signalGear position signal voltage should be higher than the following for more than 2 seconds. (Gear position switch voltage >_ 0 .6 V) Without the above value, C31 is indicated. Gear position sensor, wiring/coupler connection, gearshift cam, etc. C32 or C33 Fuel injector Crankshaft position sensor signal is produced and ECM determines the injection signal but fuel injection signal is interrupted continuous by 4 times or more. In this case, the code C32 or C33 is indicated. Injector, wiring/coupler connection, power supply to the injector C41 Fuel pump relay No voltage is applied to fuel pump although fuel pump relay is turned ON, or voltage is applied to fuel pump although fuel pump relay is turned OFF . Fuel pump relay, connecting lead, power source to fuel pump relay C42 Ignition switchIgnition switch signal is not input in the ECM . Ignition switch, lead wire/coupler C44 Heated oxygen sensor (HO2S) [For E-02, 19] During 02 feedback control, 02 sensor voltage is higher or lower than the specification . No signal is detected during engine operation or no electrical power is supplied from the battery . HO2S lead wire/coupler connection Battery voltage supply to the HO2S C49 PAIR control solenoid valve (PAIR valve) When no operating voltage is supplied from the ECM, C49 is indicated. PAIR valve can not operate. PAIR valve lead wire/coupler

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1969-1978 BMW Motorrads LED Blinker Conversion Kit Installation Instructions

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

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Disassemble all 4 blinker light assemblies as shown in Figure 2 to start the installation. Be sure to remove the lens, gasket, and bulb/reflector assembly completely. Be sure to remove the wires from the reflector assembly prior to removal from the housing. The reflector assembly will not be used any further, keep in a safe place to be stored, if desired. Figure 3 2. Figure 3 (left) shows the function with their labels on the screw terminal block locations. If planning to use the “Running Light” feature, an additional wire might be needed to be installed to use this option. If you desire to use the “Running Light” function of these LED Boards, please refer to section “How to Use the Running Light Feature of the CD1007s”for complete instructions. 3. Pull out the existing wires far enough so that they can easily reach the terminal block. Insert the correct wire in the correct location of the terminal block. Using a jeweler flat-blade screwdriver, tighten the screw to secure the wire in its location. It is highly recommend to keep the terminal block to end of the signal housing facing outward of the motorcycle, as illustrated in Figure 3 (right). Model: CD1007, LED Blinker Conversion Kit Installation Instructions For 1969-1978 BMW Motorrads: Disclaimer: Under no circumstances will Bulbsthatlast4ever or it’s representatives be responsible or liable for any incidental or consequential property damages or personal injuries arising from or in connection with the use or installation of any of the listed foregoing products or devices. Rev. 6/10 Figure 4 4. Install the screws into the lens, then place an o-ring over each screw, as illustrated in Figure 4 (left & right). The o-rings will prevent the LED Board from moving around due to vibration

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BMW R1200 RT World Sport Seat Heated Seat Installation Manual

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

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Wire the heated seat(s) and heat controller(s) per the wiring diagram included in the heated seat(s) wiring kit. This wiring diagram is also available on our website at Use the photos below to locate the recommended switched relay wire connection point, and proceed to wire the heated seat(s) and controller(s) per the wiring diagram. IMPORTANT! The BMW R1200 RT motorcycle has a single wire system or CAN (Controller Area Network) bus electrical system. You must connect the heated seat’s switched relay wire to the BMW on-board accessory jack’s hot wire or another switched wire point within the accessory circuit. While there may be many other possible connection points within the accessory circuit, illustrated below is our recommended connection point. NOTE: As an alternative, Special “Y” jack splitters are available for adding additional accessory jacks to a single jack, available from Sargent (#AC-2063) or your local BMW dealer

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