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Thread: HEXHEAD Tech - R1200RT - Plastic Removal - 2008 Model

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    Honey Badger Semper_Fi's Avatar
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    HEXHEAD Tech - R1200RT - Plastic Removal - 2008 Model

    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.

    The authors of information found here and the BMW MOA take no responsibility for ensuring the accuracy of any information (including procedures, techniques, parts numbers, torque values, tool usage, etc.), or further for any damage of any kind or injuries incurred or caused by anyone following the instructions or information found here.

    It is the duty of the individual to either assume the liability himself for responsibly using the information found here, or to take the bike or accessory to a Dealer or other qualified professional service.


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    This article, text and photos are Copyright of the individual authors and the BMW MOA, any copying or redistributing is permitted only by prior written authorization.
    Last edited by Semper_Fi; 09-29-2009 at 02:28 PM.
    2011 R1200 GSA Smoke Grey Metallic Matt
    2009 G450X White
    IBA #35651
    Rogue Moderator

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    Honey Badger Semper_Fi's Avatar
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    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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    Honey Badger Semper_Fi's Avatar
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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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  4. #4
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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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  5. #5
    Honey Badger Semper_Fi's Avatar
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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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    Last edited by Semper_Fi; 04-28-2009 at 06:08 PM.

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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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    Last edited by Semper_Fi; 04-28-2009 at 06:08 PM.

  7. #7
    Honey Badger Semper_Fi's Avatar
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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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    Honey Badger Semper_Fi's Avatar
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    There are 4 T-25 screws securing the Tank Bag Mount

    Two by the front
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  9. #9
    Honey Badger Semper_Fi's Avatar
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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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    Last edited by Semper_Fi; 04-27-2009 at 07:05 PM.

  11. #11
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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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  14. #14
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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
    Last edited by Semper_Fi; 04-28-2009 at 06:10 PM.
    2011 R1200 GSA Smoke Grey Metallic Matt
    2009 G450X White
    IBA #35651
    Rogue Moderator

  15. #15
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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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