Rear brake light switch - K-Bikes.com - Excellence in Motion
 
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post #1 of 4 (permalink) Old Sep 7th, 2013, 6:03 pm Thread Starter
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Location: Easton, MD, 21601
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Rear brake light switch

So the new to me 08 k12r won't pass Maryland inspection without the rear brake activating the tail light. So the new switch has come in and I figure this could be a job I can tackle myself....wow I've got the right side of the tank off, the battery cover the piece with the k12r badge off and still no luck. it seems that I'm going to need to remove the tank just to get to the connection. Has anyone ever changed the switch and wire? any advice?

Thanks,
Brian
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post #2 of 4 (permalink) Old Sep 7th, 2013, 8:07 pm
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Location: Chicago, IL, USA
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Best to get the reprom...

(+) Removing seat
(-) Removing seat

Use the ignition key to unlock the seat lock and hold the lock in this position.
Remove the seat.
Place the seat, upholstered side down, on a clear surface.




(+) Removing battery cover
(-) Removing battery cover

Remove 2 screws (1).
Remove the battery cover.




(+) Removing front right and left side panels
(-) Removing front right and left side panels

On each side, remove 7 screws (1, 2, 3).
Note different lengths of screws.
Disengage the lugs (arrows).
Remove the side panels.




(+) Removing right and left tank covers
(-) Removing right and left tank covers

Remove 3 screws (1, 2) from each cover.
Disengage the guide pins and remove the tank cover.




(+) Removing fuel tank
(-) Removing fuel tank

Disconnect overflow hose (1).
Remove screws (2) and carefully lift the fuel tank.
Disconnect quick-action coupling (3) and remove the fuel line.
Disconnect plugs of fuel pump (4) and fuel gauge (5).
Disconnect fuel tank breather hose (6) from the fuel-pump flange.
Lift the fuel tank up to remove.




(+) Releasing right footrest plate
(-) Releasing right footrest plate

Remove screws (1).



--------------------------------------------------------------------------------
Attention
Bent or badly routed brake lines can chafe and leak.

Take care not to bend, kink or trap the brake lines during removal and installation.
When installed, make sure that all lines are correctly routed and secured. Make sure that all components have adequate clearance, even when the handlebars are turned to full lock.




--------------------------------------------------------------------------------

Allow the footrest plate to dangle from the brake hose of the brake master cylinder, but do not place any extra strain on the brake hose.




(+) Removing rear brake-light switch
(-) Removing rear brake-light switch

Disconnect plug (1).
Cut through the cable ties at the frame and guide the cable down until clear.
Remove screw (1).
Remove the brake-light switch.




(+) Installing rear brake-light switch
(-) Installing rear brake-light switch

Hold the brake-light switch in position.
Install screw (1).


Tightening torques
Brake-light switch to footrest holder, M6 x 10
8 Nm

Connect plug (1).
Secure the cable to the frame with cable ties (arrows), making sure that the cable is correctly routed.




(+) Securing right footrest plate
(-) Securing right footrest plate


--------------------------------------------------------------------------------
Attention
Bent or badly routed brake lines can chafe and leak.

Take care not to bend, kink or trap the brake lines during removal and installation.
When installed, make sure that all lines are correctly routed and secured. Make sure that all components have adequate clearance, even when the handlebars are turned to full lock.




--------------------------------------------------------------------------------

Carefully position the footrest plate in line with the tapped holes.


Install screws (1).
Tightening torques
Front footrest holder to main frame, M8 x 20
19 Nm





(+) Function test, rear brake-light switch
(-) Function test, rear brake-light switch


Test


Connecting BMW Motorrad diagnostic system to motorcycle


--------------------------------------------------------------------------------
Note

See the Instructions for Use supplied with the Group Tester One for detailed information on initial startup, installation of the operating system, diagnosis software and hardware periphery of the GT1.

--------------------------------------------------------------------------------


Connect the BMW Motorrad battery charger (No. 61 1 581), (No. 61 1 582) to the motorcycle.


Begin by switching on and booting the BMW Motorrad diagnostic system.


The "Start Diagnosis" screen appears


From this point on, follow the instructions issued by the BMW Motorrad diagnostic system.




Test the brake-switch setting with the BMW Motorrad diagnostic system.



Result: Test result is not OK.
Measure:
Adjusting blow-by clearance at piston rod
Insert the feeler gauge transverse to the forward direction of travel between the brake switch lever and the stop screw on the footbrake lever.


Technical data
Blow-by clearance, piston rod

2 - 3 mm




Slacken nut (1) on pushrod (2).


Turn pushrod (2) until all play at the pushrod is taken up.


Lock hex nut (1) on the pushrod at the brake master cylinder hand-tight.





(+) Installing the fuel tank
(-) Installing the fuel tank

Connect fuel tank breather hose (6) to the fuel-pump flange.


Connect plugs for fuel pump (4) and fuel gauge (5).


Check O-ring of quick-release coupling (3) for damage.



--------------------------------------------------------------------------------
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.




--------------------------------------------------------------------------------

Open the latch on female coupling (3) of the fuel line and, applying light pressure, press the male adapter into the female coupling until it engages with an audible click.


Connect overflow hose (1) to the safety valve.


Position the fuel tank in the motorcycle.


Install screws (2) with spacing bushings and rubber washers.


Tightening torques
Fuel tank to retaining bridge, rear, M8 X 60
13 Nm





(+) Reading fault-code memories with the BMW Motorrad diagnostic system
(-) Reading fault-code memories with the BMW Motorrad diagnostic system

Read all fault memories.




--------------------------------------------------------------------------------
Note

When working with the BMW Motorrad diagnostic system, always follow the instructions it issues.

--------------------------------------------------------------------------------

Perform all requisite repair work.




(+) Disconnecting the BMW Motorrad diagnostic system from the motorcycle
(-) Disconnecting the BMW Motorrad diagnostic system from the motorcycle

Close all diagnostic programs and switch off the ignition.


Disconnect the BMW Motorrad diagnostic system from the motorcycle and screw the cap onto the diagnosis plug.


Disconnect the BMW Motorrad battery charger from the vehicle.




(+) Installing right and left tank covers
(-) Installing right and left tank covers

Make sure that heat insulator (1) is correctly positioned on the right-hand side.



Engage the guide pins (arrows) and install the side panel.


On each side, install 3 screws (1, 2).


Note different lengths of screws.




(+) Installing front right and left side panels
(-) Installing front right and left side panels

Hold the side panels in position.


Engage the lugs (arrows).


On each side, install 7 screws (1, 2, 3).


Note different lengths of screws.




(+) Installing battery cover
(-) Installing battery cover

Install the battery cover.


Install 2 screws (1).




(+) Installing seat

'06 K1200R- in pieces
'73 Honda CB500F- slow but fun.
'77 Yamaha XS 750 triple- kinda
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post #3 of 4 (permalink) Old Sep 7th, 2013, 8:15 pm Thread Starter
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Location: Easton, MD, 21601
Posts: 90
Now that is a process!!! Thanks so much, sounds like a fun little Sunday. Is this the type of stuff that's on the CD?
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post #4 of 4 (permalink) Old Sep 8th, 2013, 5:32 pm Thread Starter
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Location: Easton, MD, 21601
Posts: 90
JCW you are the man!

Instructions were spot on, I didn't have t remove the gas tank just disconnect the overfill hose and lift it up and to the right. I managed to get my gorilla hands in there so there should be room for anyone. Thanks again!
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