HEXHEAD Tech - R1200RT - Plastic Removal - 2008 Model

[Semper_Fi]

The articles, posts and comments in this tech section are posted by individual members and reflect their personal thoughts and experiences with repairing, maintaining, and generally working on motorcycles. This information may require specific knowledge and skills, may or may not be correct or current to model.

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[Semper_Fi]

Specifics:
- Bike shown is a 2008 R1200RT
- Heated Seat Option
- No Factory Radio
- Owner installed options of :
spaceo Gerbing Permanent Heat Control
spaceo Digital Volt Meter
spaceo Modified Accy Socket (Front) wiring harness
spaceo Centech Fuse Panel and wiring for GPS

Special Tools Needed:
– T- 25 Torx Socket
– T- 27 Torx Socket

Space: You will need a bit of space to stow away the panels as they are removed 10’ x 6’ is minimal

Process Steps:
- 1 Remove Seats
- 2 Remove Tank Bag Mounting Rack
- 3 Clutch Side Fairing – with special attention
spaceo Accessory Socket
- 4 Throttle Side Fairing – with special attention
spaceo Air Temperature Sensor Removal
spaceo Glove Box Door Removal

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SEAT REMOVAL - Pillion

If you have heated seats you need to remove the connectors for both the driver and pillion.

Shown below is the location of the connector and also the harness you need to remove to be able to take off the seat completely. The retaining clip and connector for this harness are highlighted in green.

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Unclipping the connector.

As shown below - press on the tab on the connector to be release it.

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After you remove the retaining clip for the harness from the rear seat rib, you can remove the pillion seat completely off of the bike and set it aside.

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Seat Removal - Front

If you have heated seats you need to remove the connector - similar as what was just done with the rear.

Note - there is no harness retaining clip - once removed just lay the seat aside.

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Tank Bag Mount Removal

After the seats are removed you need to take off the Tank Bag Mount

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There are 4 T-25 screws securing the Tank Bag Mount

Two by the front

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.....and two at the bottom.

Please note cabling connected to the bottom left screw is owner installed and not part of the original bike.

It is the connector for the Autocom and Gerbing.

Once the screws are removed, the tank bag rack mount can be removed off of the bike.

SHOP TIP - Keep the screws either with the removed component or placed in an identified bag – this will greatly facilitate re-assembly

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SIDE PANEL REMOVAL

Once the seats and the tank bag mount are off it does not matter which side panel is removed first.

These next steps will show the CLUTCH (LEFT) SIDE removal

The side plastic (for both sides) is comprised of what I call and upper and lower.

We remove the Upper first.

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Screw Removal Sequence - there isn't any.

Using a T-25 remove the following 4 screws

#1

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#2 of 4

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#3 and #4 of 4

Reference information – you are looking at the inside of the side panel from below the oil cooler.

Note that on stock ’08 RT’s you will not see the horn, this was added.

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UPPER SIDE PANEL REMOVAL PROCESS

Once you have removed the screws you can begin the removal process.

IMPORTANT NOTE – this side has the accessory socket and it will be connected – you need to make the disconnect of the OEM connector to physically remove the panel off the bike.

Removal process

1 – Stand facing the side panel

2 - With your right hand grasp the side with the accessory socket, with the left up by the front.

3 - Pull gently with your right hand towards you and at the same time push the panel to the front to clear the front of the bike.

4 - Check for the top black trim piece not to be hanging up on the dash panel.

5 - Walk the upper panel off of the bike - set aside and out of the way

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LOWER SIDE PANEL REMOVAL - Clutch Side

The Lower Panel consists of a very large piece of plastic which extends from the front by the dashboard, contacts the top of the tank to the driver’s seat, and around the cylinder and driver foot peg.

This process removes the entire piece.

For this panel you will need a T-25 and T-27 Torx

You will be removing 6 T-25's, 2 T-27's and 1 Plastic Twist Lock

Again no special sequence to remove the hardware.

Starting with the only plastic twist lock on the bike

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#1 of 6 T-25

Please note that this bolt is located in a unique position, I use a flexible head
1/4" drive ratchet to remove.

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#2 of 6 T-25

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#3 of 6 T-25

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#4, 5 and 6 of 6 T-25's

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The 2 T-27's are next

After the two T-27’s are removed you can lift the entire panel off the bike and remove.

Please note you have to clear the cylinder head on the lower section as it has a tendency to get hung up.

Set panel aside

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I collect all the screws removed and put them in a little plastic bag.

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THROTTLE SIDE PLASTIC REMOVAL - Upper

This is the upper panel Throttle side

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#1 of 4 T-25's

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#2 of 4 T-25

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#3 and #4 of 4

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UPPER SIDE PANEL REMOVAL PROCESS

Once you have removed the screws you can begin the removal process.

Removal process

1 – Stand facing the side panel

2 - With your right hand grasp the side with the front highlighted in yellow, with the left grasp by the rear highlighted in green.

3 - Pull gently with your left hand towards you and at the same time push the panel to the front to clear the front of the bike.

4 - Check for the top black trim piece not to be hanging up on the dash panel.

5 - Walk the upper panel off of the bike - set aside and out of the way

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A point of interest on the right side panel removal is the AIR TEMP SENSOR.

This has been relocated from previous position in the rear, I think this occured at MY 2006 and above but may be wrong.

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There are two ways to remove the sensor.

1 is unclip and let dangle

2 is disconnect the sensor and remove the harness from the retaining clips.

I use option two as this minimizes scuffing and scratching the paint on the lower panel.

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Once the air temp sensor is disconnected off of the panel you can proceed to remove the lower panel.

There is another item to be aware of and that is the 2 short length - T25 screws.

These belong to the hinge for the glove box door.

- IT IS CRITICAL - that these go back where they belong as longer T-25's will puncture gas tank

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Continuing with the upper side of the lower panel are 4 T-25's

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Remove the T-25 screw on top by the tank.

Note the tight working area - hence the use of the short ratchet with no extension.

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Remove the lower gas tank T-25.

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Remove the T-25 by the seat area

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Remove the last 3 T-25's and you only have the two T-27's to remove

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After the two T-27’s are removed you can lift the entire panel off the bike and remove.

Please note you have to clear the cylinder head on the lower section as it has a tendency to get hung up.

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This completes the plastic removal.:dance

At this stage you should have the plastic off for the right and left side.

You should be able to access the air cleaner and gas tank.

The screws below are what was removed from the right side - you should set then aside in a way that they will be correctly returned.

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RE-ASSEMBLY HINTS

1 - The bike is very well designed and goes back together very easily - if you are finding yourself you are forcing something - STOP - because something is wrong.
2 - All panel mount centers fall exactly in place to the mounting centers if properly placed.
3 - hand start all the screws for proper thread engagement and then when the respective panel is fully in place with all the screws/mounting hardware - then tighten

Right side:

- hang the lower panel, connect the air temp sensor
- use the smallest screws (2 T-25) for the hinges of the glove box door.
- mount the upper fairing

Left Side
- hang the lower panel
- connect the ACC Wiring to the upper panel
- mount the upper panel