BMW R1200GS User manual

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BMW R1200GS Motorcycle (W348)
Customer Service Guide
MMXV © Copyright Rollplay

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Customer Service Guide
Contents
I) Check Battery …………………………............................................. 3
II) Check Wiring Condition ……………………………..………………………. 6
III) Windshield Replacement ……………………………………………..….…. 9
IV) Gearbox Replacement ……………………………………………………… 10
V) Warning Stickers ……………………………………………..…….………… 14
VI) Schematic diagram ……………..…………….…..….………..…………. 17
VII) Exploded View ………………………....…....….……….……..……..…18
CAUTION :
Disconnect the battery before proceeding
with the following steps.

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Customer Service Guide
I) Check Battery
Operation: Use a Flat head screwdriver to unlock and remove the seat. Locate the
battery harness, unplug the connector, and then use a volt-meter to check the
condition of the battery.
Step (1)
Turn and unlock this plastic knob
Step (2)
Unlock position

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Customer Service Guide
I) Check Battery
Step (3)
Lift up the seat cover from the rear end
Step (4)
Unplug the battery connector underneath the seat

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Customer Service Guide
I) Check Battery
Step
(5)
Reading Judgment: 6.0 V ~ 6.5 V –Good condition
5.6 V ~ 5.9 V –Recharge battery
5.5 V –Recharge battery. If after the stipulated
recharging time the voltage has not
increased, then replace the battery.
Below 5.5 V –Replace the battery.

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Customer Service Guide
II) Check Wiring Connection
Operation: There are two wiring connections that should be checked.
A. Motor/Gearbox : Turn over the vehicle and locate the Gearbox harness at the
bottom.
Step (1)
The motor harness is near the rear wheel
Step (2)
Check the white connectors. Disconnect, then reconnect these connectors.

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Customer Service Guide
II) Check Wiring Connection
B. Handlebar/Sounds : Disassemblethe windshield and check the two
connections per the below procedures.
Use a flat screwdriver to remove the bracket next to the windshield
Step (1)
Release the latch at the front
Step (2)

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Customer Service Guide
II) Check Wiring Connection
Step (3)
Lift up the whole windshield
Check for any loose connectionson the handlebars.
Step (4)
Reverse the above procedures to reassemble the vehicle.

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Customer Service Guide
III)Windshield Replacement
Operation: Follow the procedure (IIb) to detach the windshield,and then unplug the two
connectors to remove it completely for replacing.
Replace the Handlebar sub-assembly with a new one.
Reverse above procedures to re-assemble the vehicle

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Customer Service Guide
IV)Gearbox Replacement
Operation: Follow below steps to replace the gearbox.
Use the two plastic wrenches to remove the nuts at both sides
Step (1)
Step (2)
Unscrew the motor cover on the left side of rear wheel.

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Customer Service Guide
IV)Gearbox Replacement
Step (3)
Hold and pull out the motor cover as shown.
There are two latches help to hold the cover in place
Step (4)

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Customer Service Guide
IV)Gearbox Replacement
Slide the rear axle out from the opposite side of the
gearbox. There is no need to remove it completely, just
enough to release the gearbox.
Step (5)
Step (6)
Remove the gearbox from the rear wheel assembly.

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Customer Service Guide
IV)Gearbox Replacement
Unplug the motor connector (white)
Step (7)
Step (8)
Replace the gearbox
with a new/good one
Reverse above procedures to re-assemble the vehicle

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Customer Service Guide
V)Warning Stickers
Operation: Check and re-put the damaged warning stickers after repairing.
(1) Bottom side of car body (underneath of rear fender)

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Customer Service Guide
V)Warning Stickers
(2) Bottom side of Seat

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Customer Service Guide
V)Warning Stickers
(3) Battery harness

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Customer Service Guide
VI) Wiring Schematic

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Customer Service Guide
VII)Exploded View