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View Full Version : Plastic Removal for 2005 R1200ST


Semper_Fi
09-17-2009, 04:34 PM
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Semper_Fi
09-17-2009, 04:38 PM
The R1200ST is another Hexhead variant with a different set of plastic design for the fairing and side panels.

This DIY will show how to remove those panels for servicing the bike.


There are actually 3 main parts per side which need to be removed to have complete access to the bike.

The tools you will need are the following:


T-20 Torx
T-25 Torx
1/4 drive Ratchet
1/4 drive speed handle (optional)
1/4 drive extension

Semper_Fi
09-17-2009, 05:44 PM
Starting on the left (clutch) side for no particular reason.

The overall process is:


First remove the seats, driver and pillion (not shown)
Remove the windshield guide slot cover
Remove top front panel
Remove the main left side panel
Remove the lower side panel


Repeat for the right (throttle) side

Semper_Fi
09-17-2009, 05:47 PM
Using a T-20 torx remove the screws retaining the Windshield Guide Slot cover

Semper_Fi
09-17-2009, 05:50 PM
Remove the guide cover by pulling straight up

Semper_Fi
09-17-2009, 05:52 PM
Note that the screws for the Windshield Guide Slot covers are not regular machine screw thread but plastic thread forming as noted below

Semper_Fi
09-17-2009, 05:53 PM
Using a T-25 torx remove the two retaining screws for the top front left panel

Semper_Fi
09-17-2009, 05:54 PM
With a T-25 remove the indicated screw by the rear of the top front panel as shown

Semper_Fi
09-17-2009, 05:55 PM
Pull out the top panel

Semper_Fi
09-17-2009, 05:57 PM
Before removing the main side panel you need to remove the very lower side panel as it is integrated into the other.

Using a T-25 remove indicated screw

Semper_Fi
09-19-2009, 01:15 AM
Detail of the back side of the lower panel.

Note the that there are two grommet panel

Semper_Fi
09-19-2009, 01:21 AM
Remove the lower bottom screws (T-25) of the main side panel as shown.

Semper_Fi
09-19-2009, 01:25 AM
With all the screws removed you can now lift off the main side paenl.

Please note that there are 3 tongue and groove locations which essentially clip in and retain the piece in place.

Lift carfefully and disengage the panel

Semper_Fi
09-19-2009, 01:26 AM
Left Side Plastic removed

Semper_Fi
09-19-2009, 01:41 AM
Using a T-20 removethe screw retaining the right side windshield guide cover.

Semper_Fi
09-19-2009, 01:47 AM
Renove the indicated 5 T-25 screws and then remove the front top panel

Semper_Fi
09-19-2009, 01:50 AM
Remove the lower right side panel screw (T-25) and pull off panel

Semper_Fi
09-19-2009, 01:56 AM
Remove the indicated T-25 screws and remove the main right side panel.

Semper_Fi
09-19-2009, 02:02 AM
The same tongue and groove features on the left side main panel are found on the right.

The same care is needed to remove.

Semper_Fi
09-19-2009, 02:08 AM
The re-assembly is straight forward and identical for both sides


Install Top Panel
Mount Main Side Plastic, paying attention to the tongue and grove features to locate and capture the panel in place
Install Lower Side Plastic and mate onto the plastic features into the grommets
Install the Windshield Guide Covers