index

Replacing ESA spring strut, front, for conversion

Electronic Suspension Adjustment (ESA)

Preparatory work

Removing engine guard

Remove screws (8) and (7) with washers (6).

Remove nuts (9) and remove engine guard (1).

Remove buffer (3).

Remove nut (5).

Remove screw (2).

Remove holder (4).

Installing engine lifter

Secure engine adapter (No. 00 1 572) to the engine with screw (1), nut (2) and screws (3).

Push scissor-type lifter (No. 00 1 571) with extension (No. 00 1 575) into the engine adapter

Tighten knurled screws (4) and slightly raise the motorcycle with the engine lifter.

Removing front and rear seats

Removing left side cover

Unclip side cover (1) from the holders (arrows) and remove.

Remove the right side cover

Remove screw (1).

Unclip side cover (2) from the holders (arrows) and remove.

Removing right side panel

Remove screws (1) and (2).

Remove side panels (3).

Removing left trim panel of fuel tank

Remove screws (1).

Disengage the lug (arrow) for the centre cover of the fuel tank and remove cover (2).


	Removing right trim panel of fuel tank

Remove screws (1).

Disengage the lug (arrow) for the centre cover of the fuel tank and remove cover (2).

Removing intake air pipe

Disengage retainer (1) by pressing at rear and remove.

Pull the locator (arrow) to the side and out of the rubber sleeve and remove intake air pipe (2).

Removing fuel tank

Remove screws (1) on left and right.

Warning

Fuel is flammable and a hazard to health.

Observe all applicable safety regulations.

Disconnect fuel delivery line (2).

Disconnect plug for fuel pump (3) and plug for fuel level sensor (4).

Disconnect fuel return line (5).

	Disconnect breather hose (6) and overflow hose (7) at the connectors (arrows).
	Remove screws (8) with washers (9) and rubber washers (10) on left and right. Lift the fuel tank up and to the rear to remove.

	Removing side section, left crash bar
	Remove screw (1).

Remove screw (2) with washer (3) and bushing (4).

Remove side panel (5).

Removing side section, right crash bar

Remove screw (1).

Remove screw (2) with washer (3) and bushing (4).

Remove side panel (5).

Removing centre section of crash bar

Remove screws (1) and (2) on left and right.

Carefully remove centre section (3).

Removing belt guard

Remove screws (1) and (2).

Remove the belt guard.

Core activity

Removing front spring strut (manufacturer SHOWA)

Part no 31427702732

Remove the cable ties (arrows).

Disconnect ESA plugs (1) and (2).

Work the ESA cables down.

Remove screws (3) with washers (4) and at top with nuts (5).

Remove nut (5), while counter-holding at the spring-strut stud.

Remove washer (6) and spacer buffer (7).

Remove screw (8).

Raise the motorcycle with the scissor-type lifer and work the spring strut forward to remove.

Remove sleeve (9) and spacer buffer (10).

Install the front spring strut (manufacturer WP Suspension)

Part no 31427728210 about 1.452,00 EUR

Clean the threads.

Position spacer buffer (10) with the collar up.

Place sleeve (9) in position.

Install the spring strut.

Lower the motorcycle on the scissor-type lifter.

Place rubber buffer (7) in position with the collar down and install washer (6).

Apply thread-locking compound to nut (5) and tighten until hand-tight.

Fluids and lubricants
Loctite 243	Thread-locking compound	83 19 0 210 339

Install screw (8).

Tightening torques

Spring strut, front, to leading link

M10 x 50 x 1.25 - 10.9, Replace screw, lubricate head

Micro-encapsulated, Optimoly TA

Clip the anti-twist stop into position (arrow) and latch.

Latch (4) engages with an audible click.

Secure cable holder (3) in the anti-twist stop.

Tighten nut (5), while counter-holding at the spring-strut stud (arrow).

Tightening torques

Spring strut to front frame

Hex nut, M10 x 1.25

Loctite 243

34 Nm

Make sure that anti-twist stop (4) does not twist.

Turn the handlebars all the way to the left and make sure that the ESA motor clears the fork leg.

Work the ESA cables up into position.

Connect ESA plugs (1) and (2).

Secure the lines with cable ties (arrows).

Finishing work

Installing belt guard

Install the belt guard with screws (1) and (2).

Installing centre section of crash bar

Carefully manoeuvre centre section (3) into position until, on the left-hand side, it is resting against the flange of the oil line (arrow).

Loosely install screws (2) on left and right.

Install screws (1) on left and right.

Tightening torques
Tank guard to crash bar
M8 x 40	19 Nm

Installing side section, left crash bar

Tighten screw (2) with washer (3) and thick bushing (4) a few turns.

Hold side panel (5) with C-section in position between washer (3) and bushing (4).

Further tighten screw (2) to secure the side panel.

Loosely install screw (1).

Installing side section, right crash bar

Tighten screw (2) with washer (3) and thin bushing (4) a few turns.

Hold side panel (5) with C-section in position between washer (3) and bushing (4).

Further tighten screw (2) to secure the side panel.

Loosely install screw (1).

Secure the crash bar

Tighten screws (1) on left and right.

Tightening torques
Crash bar to crankcase
M10 x 30	25 Nm

Tighten screws (2) on left and right.

Tightening torques
Tank guard to fairing bracket/crash bar
M6 x 16	9 Nm

Tighten screws (3) on left and right.

Tightening torques

Crash bar to front frame

M6 x 16, Replace screw

Mechanical thread lock

9 Nm

Installing fuel tank

Push the fuel tank from behind into the rubber mounts on the frame. Make sure that no lines, hoses or Bowden cables are trapped.

Connect breather hose (6) and overflow hose (7) at the connectors (arrows).

Work the trim panel into position at the top wheel cover (detail).

Install screws (1) on left and right.

Install screws (8) with washers (9) and rubber washers (10) on left and right.

Tightening torques
Fuel tank with bracket to front frame
M8 x 40	19 Nm

Check the O-rings in quick-action coupling (2) for damage; replace if necessary.

Lubricate the quick-action couplings to facilitate assembly.

Fluids and lubricants
Molykote 111	Silicone grease	11 00 7 660 832

Attention

Lightly touching the latching pin of the female connector can cause the connector to latch. If this happens and force is applied in an attempt to close the male and female elements of the quick-action coupling, damage to the O-rings can result, and the O-rings will leak.

Make sure that the latch is open/pressed when you connect the two elements of the quick-action couplings in the fuel lines.

Open the latches on the female coupling of delivery line (2) and, applying light pressure, press the male adapter into the female coupling.

The female coupling engages with an audible click.

Connect plug for fuel pump (3) and plug for fuel level sensor (4).

Connect fuel return line (5).

Installing intake air pipe

Slide intake air pipe (2) into position and push in retainers (1) until they engage with an audible click.

Push the retaining pin (arrow) fully home in the rubber sleeve.

Check that the throttle-valve cable is seated in the guide of the air intake pipe (arrow) and that it is has not been pulled out of the divider (detail).

Installing right trim panel of fuel tank

Hold cover (2) in position and engage the lug (arrow) for the centre cover of the fuel tank.

Install screws (1).

Install the right trim panel of fuel tank

Hold cover (2) in position and engage the lug (arrow) for the centre cover of the fuel tank.

Install screws (1).

Installing right side cover

Hold side panels (3) in position.

Install long screws (1).

Install short screws (2).

Installing left side panel

	Hold side cover (1) in position and push the snap-fit studs into the holders (arrows).

Installing right side cover

Hold side cover (2) in position and push the snap-fit studs into the holders (arrows).

Install screw (1).

Connecting BMW Motorrad diagnostic system to motorcycle

Note
See the information about the BMW Motorrad diagnostic system for all other instructions.

Connect the BMW Motorrad battery charger.

Workshop equipment

BMW Motorrad battery charger (version for Europe without GB)

BMW Motorrad battery charger (GB/AUS/NZL version)

BMW Motorrad battery charger (Japan version)

BMW Motorrad battery charger (USA/CAN version)

Begin by switching on the BMW Motorrad diagnostic system and wait for it to power up.

The *Start Diagnosis* screen appears

From this point on, follow the instructions issued by the BMW Motorrad diagnostic system.

Retrofit with CIP (Coding, Individualisation and Programming) or ISTA P

Precondition

Engine is off.

Battery is fully charged and battery charger is connected.

Note

Do not attempt to perform work of any other kind on the motorcycle while programming/coding is in progress.

Switch off all electrical consumers.

Begin by switching on the BMW Motorrad diagnostic system and wait for it to power up.

From this point on, follow the instructions issued by the diagnostic system.

Perform diagnosis. Rectify faults, if found, before starting programming/coding.

Start programming/coding with the CIP program and follow the instructions issued by the diagnostic system.

Select the retrofit just completed from the range offered in CIP and step through the rest of the procedure.

Disconnecting BMW Motorrad diagnostic system from motorcycle

	Terminate the diagnosis session correctly and switch off the ignition. Disconnect KOMET from the motorcycle and screw the cap onto the diagnosis plug. Disconnect the BMW Motorrad battery charger from the motorcycle.

	Installing front and rear seats

Removing engine lifter

Lower the motorcycle with the engine lifter and place it on its side stand.

Slacken knurled screws (4) and pull scissor-type lifter (No. 00 1 571) with extension (No. 00 1 575) out of the engine adapter.

Remove nut (2) and screw (1).

Slacken screws (3) and remove engine adapter (No. 00 1 572).

Installing engine guard

Fix holder (4) to the crankcase with screw (2) and nut (5).

Hold engine guard (1) in position and install buffers (3) and nuts (9) at rear.

Install screws (8) and (7) with washer (6).

Align holder (4) and tighten nut (5).

Tightening torques
Bracket, engine guard to crankcase
M10 x 90	40 Nm

Tighten nuts (9) and screws (7) and (8).

Tightening torques
Engine guard to engine
Rear, Nut M8	19 Nm
front left, M8 x 20	19 Nm
front right, M6 x 10	8 Nm

Final check of work performed

Check that

- the work as performed achieved the intended purpose.

- all reservoirs and containers have been filled and that all fluids and lubricants are at their correct levels.

- all threaded fasteners released beforehand have been correctly retightened.

- the fuel system is free of leaks.

- the lights and signalling equipment are fully operational and that the motorcycle is roadworthy.

- the brake pads of the front and rear brakes are bedded against the brake discs.

Repair Manuals R 1200 GS Adventure (0380) (6. edition, 03/2011)