Installing on-board socket (Repair Manuals 6th edition Part number 01059 7 721 683)

BMW R 1200 GS Adventure (0380)

 
 

Equipment trim-level variant:
       

Extra socket
 
   
   
   
  Preparatory work
 

Removing front and rear seats
 

Removing left side cover
 

Removing left side panel
 

Remove the right side cover
 

Removing right side panel
 

Removing right trim panel of fuel tank
 

Removing intake air pipe
 

Removing slipstream deflector, left
  Core activity
 
(-) Affixing drilling template for on-board socket
 
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Clean and degrease the fairing.
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Peel the backing paper off the drilling template.
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Position the drilling template along the edge (arrow), centre it relative to the land and glue it into position.
 
(-) Drilling pilot hole in font-wheel cover for on-board socket
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Check that clearance underneath the front-wheel cover is adequate for drilling and that there is no danger of damaging lines, cables or similar in the process.
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Use a scriber to mark the centres on the front-wheel cover at positions (1) and (2).
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Drill a hole at position (1).
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Drill to correct diameter with twist drill

  

4 mm

 
 
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Drill a pilot hole at mark (2) and use a centre bit to drill out the hole to the correct size to accommodate the power socket.
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Drill the pilot hole at mark and drill hole to size

Drill pilot hole to correct diameter with twist drill

4 mm

 

Drill out to correct diameter with centre bit

18 mm
 
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Remove the drilling template.
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Deburr the hole.
 
(-) Removing fuel tank
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Remove screws (1) on left and right.
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Warning

Fuel is flammable and a hazard to health.

Observe all applicable safety regulations.
 
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Disconnect fuel delivery line (2).
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Disconnect plug for fuel pump (3) and plug for fuel level sensor (4).
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Disconnect fuel return line (5).
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Disconnect breather hose (6) and overflow hose (7) at the connectors (arrows).
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Remove screws (8) with washers (9) and rubber washers (10) on left and right.
 
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Lift the fuel tank up and to the rear to remove.
 
(-) Installing on-board socket in front-wheel cover
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Seat on-board socket (1) in the hole drilled to accommodate it in the front-wheel cover.
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Install spacer (2) in the hole with the projection (arrow) toward the front.
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Tighten nut (3).
 
(-) Removing tool compartment and preparing for wiring
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Open strap (1) and remove tool compartment (2).
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Disconnect plug (3) of the standard on-board socket.
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Open the cable tie (arrow).
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Remove screw (4) from the rear-wheel cover.
 
(-) Routing cable for on-board socket
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Connect plug (1) of adapter cable (2) to standard on-board socket (3).
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Connect plug (4) of adapter cable (2) to plug (5) of the wiring harness.
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Secure the plugs with a cable tie (arrow).
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Press the rear-wheel cover down slightly and work the adapter cable forward through the opening.
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Route adapter cable (2) forward between the rear-wheel cover and the frame tube.
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Secure adapter cable (2) with cable ties (arrows).
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Route adapter cable (2) forward parallel with the wiring harness and secure it with cable ties (arrows).
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Check that the Bowden cables have not been pulled out of divider (6), as otherwise the throttle valves would no longer be able to reach their limit stops.
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Clip adapter cable (2) into holder (7).
 
(-) Installing tool compartment
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Install screw (1) in the rear-wheel cover.
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Install tool compartment (2).
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Secure strap (3).
 
(-) Installing fuel tank
 
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Push the fuel tank from behind into the rubber mounts on the frame. Make sure that no lines, hoses or Bowden cables are trapped.
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Connect breather hose (6) and overflow hose (7) at the connectors (arrows).
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Work the trim panel into position at the top wheel cover (detail).
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Install screws (1) on left and right.
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Install screws (8) with washers (9) and rubber washers (10) on left and right.
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\Anziehdrehmoment.gif Tightening torques

Fuel tank with bracket to front frame

M8 x 40

19 Nm

  
 
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Check the O-rings in quick-action coupling (2) for damage; replace if necessary.
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Lubricate the quick-action couplings to facilitate assembly.
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Molykote 111

Silicone grease

11 00 7 660 832
 
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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.
 
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Open the latches on the female coupling of delivery line (2) and, applying light pressure, press the male adapter into the female coupling.
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The female coupling engages with an audible click.
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Connect plug for fuel pump (3) and plug for fuel level sensor (4).
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Connect fuel return line (5).
 
(-) Connecting on-board socket
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Connect plug (2) to on-board socket (1).
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Secure the cable with a cable tie (arrow) in such a way that cap (3) of the fuel-pump unit can still be removed and installed.
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Turn the handlebars to the full left and right lock positions.
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Make sure that movement is not obstructed by the newly installed cable.
 
(-) Function check and fuse protection
 
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Check operation by connecting a suitable commercially available 12V device to the socket.
 
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Note

All circuits are electronically protected, so plug-in fuses are no longer necessary. If an electronic fuse trips and de-energises a circuit, the circuit is active as soon as the ignition is switched on after the fault has been rectified.
 
D:\BMW\RepROM_K2x_GS\Datas\RepRom\BMW-Motorrad\SYMB\KG\MODELLE\00\techdat.gif Technical data

Electrical rating of on-board sockets

Total for all sockets

max 5 A

  
 
 
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Also check the latching function of the socket cover; slowly open the cover and release it: the cover must remain open.
  Finishing work
 

Installing left slipstream deflector
 

Installing intake air pipe
 

Install the right trim panel of fuel tank
 

Installing right side panel
 

Installing right side cover
 

Installing left side panel
 

Installing left side cover
 

Installing front and rear seats
 

Final check of work performed