BMW R 1200 CL User manual

Motorcycles
Technical
Training
BMW Motorcycles
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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.

1
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

2
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

3
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

4
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

5
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

6
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

7
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

8
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

9
The engaging and disengaging gears are
located on the auxiliary shaft and the driven
shaft. All driven gears are installed on low-
friction 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 alu-
minum.
The aluminum shifter drum is fixed in the
exact gear positions by a cam plate. The
die-cast aluminum shifter forks are actuat-
ed 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 qui-
etly running, wear-resistant spiral gearing.
All other gears are provided with a spur
toothing and are constructed tightly inter-
locked.This provides smoother meshing for
particularly quiet running.
The hollow-bored drive shaft bears a com-
pact, two phase starting damper. The rota-
tional oscillations occurring during the idle
speed of the engine are absorbed by a pre-
stressed washer. A heavy-duty coil spring
works in the main damper, which is respon-
sible for reducing the noise occurring dur-
ing the changing of gear and load.
R 1200 CL
Gear Box
Technical Features in Detail

10
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.
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 grad-
ually changes as the engine warms up.
R 1200 CL
Digital Motor Electronics MA 2.4
Technical Features in Detail

11
The fuel pump – together with a fuel pres-
sure 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 (Alpha-
n-control) via the angle of the throttle valve
(Alpha) and the engine speed. The fine-tun-
ing 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 pro-
grammed characteristics in the control unit.
R 1200 CL
Digital Motor Electronics MA 2.4
Technical Features in Detail

12
The output signals for ignition and injection
are amplified in the control module by inte-
grated output transistors. The transistors
switching on and off activates the fuel injec-
tor solenoid valves and the primary ignition
coil windings.
The cold-start control works with an actua-
tor with a worm gear pair that directly actu-
ates 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.
The fuel injectors are small and light weight.
They inject fuel once per crankshaft revolu-
tion 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.
R 1200 CL
Digital Motor Electronics MA 2.4
Technical Features in Detail

13
The Motronic is equipped with a fuel cut-off.
If throttle valves are closed, an engine tem-
perature is more than 70° C or an engine
speed exceeds 1800 rpm, then the activa-
tion 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 moni-
toring 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 diagnos-
tic equipment (MoDiTeC / GT 1) via the 10
pin diagnostic plug located under the left
side chrome cover.
R 1200 CL
Digital Motor Electronics MA 2.4
Technical Features in Detail

14
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 deci-
sion, 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
Additionally, the attachment points for the
brake calipers had to be modified to com-
ply with the EVO caliper dimensions requir-
ing 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 maintenance-
free 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 alu-
minum, upper fork bridge. The fork bridge
steering bearings are reinforced double-
row flute bearings.
R 1200 CL
Chassis and Wheels
Technical Features in Detail

15
R 1200 CL
Chassis and Wheels
Technical Features in Detail
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.

16
R 1200 CL
Chassis and Wheels
Technical Features in Detail
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 geom-
etry we will compare the R 1200 C to the
CL. But first lets review the basics of chas-
sis 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 imagi-
nary axis line of the steering pivots would
contact the ground.
By itself, the 30mm longer R 1200 CL
Telelever changes the rake angle to 56O
and increases the wheelbase by the same
distance.
However, the new lower fork brace reposi-
tions the steering pivot further forward on
the fork brace, which moves the forks rear-
ward reducing the overall wheelbase but
increases the trail.
Final chassis specifications of R 1200 C
vs R 1200 CL:
Rake angle:
C = 60.5O
CL = 56O
Trail measurement:
C = 86mm (3.38“)
CL = 184mm (7.24“)
Wheelbase:
C = 1650 mm (65.0“)
CL = 1641 mm (64.61“)

17
R 1200 CL
Chassis and Wheels
Technical Features in Detail
The Monolever swing arm is fixed very rigid-
ly – in central cast steel parts – in backlash
free taper roller bearings, thereby resulting in
a short, rigid connection between the bear-
ing of the rear wheel swing arm and the lon-
gitudinal control arm.
The welded monolever consists of extreme-
ly 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 ten-
sion struts of the frame triangle.
The new spring strut is equipped with a sin-
gle 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.

18
R 1200 CL
Chassis and Wheels
Tail Frame Section
Front Wheel
R 1200 CL Introduction
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.
Due to the longer seat system and the addi-
tion of the top case, the rear frame is
lengthened accordingly. The side cases are
mounted to tubular frame extensions pro-
viding a screw mounting point.The left side
extension is removable for tire service by
removing four screws.