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#111065 - 07/06/06 02:55 AM R1200RT Ohlins Installation Part 1  
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Limecreek Offline
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Limecreek  Offline
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Leander, TX
Ohlins Installation R1200RT



Part 2 will be published after I square away a problem I am having with the front shock. The threaded stud on the front shock was not installed properly and is 1/2" too long. More on that later--looks to be a minor and an easy fix anyway. The rear shock was very easy to do taking no more than an hour from start to finish.

Part 1—ESA Rear Shock Removal and Ohlin Shock Installation

Gather your tools:

• Torx T-35, T-45, T-50, T-20, T-15 and the T-50 key out of your BMW kit
• 3/8 Drive Ratchet
• Ratchet extension – short one will do
• 15mm socket
• 15 mm offset wrench
• 6 mm hex wrench
• 5 mm hex wrench
• Torque wrench
• Tie clippers
• Blue loctite
• Torch (if smoking cigar)
• Cutter (if smoking cigar)
• Scissor jack
• Short board
• Flashlight



Read the BMW manual prior to attempting the installation on your own and refer to it as needed during the process. If you have any doubt as to your ability, spend the money and take it to your dealer or better still, suck up to one of your buddies that does this stuff in his or her sleep and ask them to do you a favor.

Ok, here we go:

Removing the Rear ESA Shock

1. Remove the seats.
2. Remove the silencer—you’ll need a T-45 torx for the bolt to the frame and a 15 mm wrench to release the exhaust clamp.


3. Remove the rear wheel—you’ll need a T-50 torx, a ratchet and extension.


4. Remove the lower inner mud guard—look for the cable on the right hand side and remove it.


5. Follow the cable from the rear shock up the right hand side of the motorcycle. Cut the zip tie holding the harness and find all three plugs and disconnect them, being careful to squeeze them while pulling them apart. Pull the plugs apart not the wires.




6. Support the swing arm with the scissor jack.


7. Remove the lower bolt—T-50 torx.


8. Remove the top bolt—T-50 torx key and 15 mm wrench or socket.


9. Pull the shock out the bottom being careful to route all the wires out with the shock.

The rear ESA shock weighs 12 pounds—sheesh.


Installing the Ohlin Rear Shock

1. Install the rear Ohlin shock passing it up through the center of the swing arm.
2. Align the preload cable to the left and pass the preload adjuster up and over the frame and down and out the left side of the motorcycle—you’ll mount that later.


3. Insert the bolt at the top of the shock.
4. Insert and thread in the bottom bolt—blue loctite the bottom bolt.
5. Tighten the bottom bolt to 20 Nm, and then finish by tightening to 58 Nm.


6. BMW want you to replace the nut for the top bolt. I didn’t, but plan to purchase a new nut and will install it at a later date.
7. Tighten the top nut to 50 Nm.
8. Attach the preload adjuster to the outside of the frame. Actually, you could attach it under the seat somewhere if you don’t want it on the outside—up to you.


9. Install the lower mudguard.
10. Install the rear wheel—tighten in a diagonal pattern and to a final torque of 60 Nm.
11. Install the silencer, align the clamp and torque to 55 Nm and torque the frame attachment to 19 Nm.

Part 2 out in a couple of days--the front shock.

#111066 - 07/06/06 03:06 AM Re: R1200RT Ohlins Installation Part 1 [Re: Limecreek]  
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Whip Offline
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San Antonio, TX
Great work...you even cleaned the old shock before you took the pix.......

Whip


I am their leader, which way did they go?
#111067 - 07/06/06 03:12 AM Re: R1200RT Ohlins Installation Part 1 [Re: Limecreek]  
Joined: Mar 2006
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russg Offline
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Posts: 323
Newport News, VA, USA
Nice work.

Out of curiosity and since I haven't really had my seat off that much, can someone tell me what that do-hickey is in the third picture from the bottom, center below the shock mount and to the left of the brake fluid fill cap. It appears to have an adjustment knob on it? Square on one side and round on the side with the knob.

I may just have to got look at my bike now. :D
--russ


--russ
l
'06 R1200RT
'04 Connie (sold)
'98 Marauder (sold)
'85 Mandura (sold)
'81 Sportster (sold)
#111068 - 07/06/06 03:31 AM Re: R1200RT Ohlins Installation Part 1 [Re: russg]  
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duckbubbles Offline
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duckbubbles  Offline
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Austin, Texas, USA
That is the port for connecting the computer interface to the bike.

Frank


2017 R1200RS, 2 mo. 7000 mi.
2016 R1200RS, 18 mo. 28,322 mi. (gone)
1985 K100/1100RS, 32 yrs. 325,000 mi.
2005 R1200ST 8 yrs.(The Deerslayer)3rd deer killed it
2011 R1200RT 2 yrs. (gone)
#111069 - 07/06/06 03:41 AM Re: R1200RT Ohlins Installation Part 1 [Re: Limecreek]  
Joined: Apr 2003
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Ken H. Offline
Turtle Whacks
Ken H.  Offline
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Posts: 16,404
Edmonton, AB Canada
Very nice write up!

Questions...

Did you make the adjuster bracket yourself, or is that an Ohlins part?

Now that the ESA shock is gone, how does your ZFE and display modules behave? Any displayed errors?


Ken & Donna H.
Doctor – I need to learn how to relax faster.

If you want to ride tomorrow, ride quietly today.
Quiet is cool, silent is sexy.
#111070 - 07/06/06 11:22 AM Re: R1200RT Ohlins Installation Part 1 [Re: Ken H.]  
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Limecreek Offline
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Leander, TX
The bracket is an Ohlins part. The ESA display is unchanged. I can toggle through all of my adjustment choices like I could before I pulled the shocks. No errors--so far.

I need a way to cap all of the ESA plugs on the bike to avoid corrosion. If anyone has a suggestion I am all ears.

#111071 - 07/06/06 12:38 PM Re: R1200RT Ohlins Installation Part 1 [Re: Limecreek]  
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Highway41 Offline
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Highway41  Offline
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Jax, Fl
Cut the connections off the shock, tape the ends, and plug 'em back into the bike connectors.
Am interested in the ride campario to the ESA shocks.
Bill

#111072 - 07/06/06 01:24 PM Re: R1200RT Ohlins Installation Part 1 [Re: Highway41]  
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Limecreek Offline
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Limecreek  Offline
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I want to keep the ESA shocks functional in case a future owner wants to return the bike back to stock so cutting the plugs off is not an option.

I'm still sorting out my front shock problem with Ohlins so it may be next week before I get out for a test ride.

#111073 - 07/06/06 01:35 PM Re: R1200RT Ohlins Installation Part 1 [Re: Limecreek]  
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crashtapper Offline
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S. E. Wisconsin
Thanks for the great write-up, and I'm looking forward to the front installation. You are removing a significant veil of mystery for me, extremely clear. Please include your address so I can hang around your garage!

#111074 - 08/21/06 03:37 PM Re: R1200RT Ohlins Installation Part 1 [Re: crashtapper]  
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Fran Offline
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Fran  Offline
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Paxton, MA
Does the installtion of front and rear Ohlins raise the ride height? I am considering them but don't want the bike any taller than it already is.

Thanks
Fran

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