77 51 001 Installing LED auxiliary headlights

BMW-Motorrad - 0450 - R 1200 GS, K25 31
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77 51 001 Installing LED auxiliary headlights (14 FRUs)
77 51 502
Equipment trim-level variant:
LED auxiliary headlights
OA
Note
Not all the components contained in the installation kit are necessary for
installing the auxiliary headlights.
Note
Conversion/retrofit also work without registration with the BMW Motorrad
diagnostic system. Registration is advisable, however, so that they will
subsequently be detected by the system whenever work is carried out with
the diagnostic unit.
Note
The LED auxiliary headlights have an overheat cutout. The headlights
automatically reduce their brightness if a certain temperature is reached;
under extreme circumstances the headlights can even switch themselves off.
The headlights return to full brightness once they have cooled down
sufficiently.
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 trim panels of fuel tank
Removing intake air pipe
Removing fuel tank
Core activity
(-) Preassembling brackets for both sides
Seat nut (1) in bracket (2).
Insert LED auxiliary headlight (3) into bracket (2).
Tighten screws (4) just tight enough to hold the LED auxiliary headlight in
position, so that beam throw can subsequently be adjusted.
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(-) Installing brackets with LED auxiliary headlights on both
sides
Remove screws (1); these screws are no longer needed as longer screws
will be installed instead.
Slip flat nuts (2) onto fairing bracket (3) (arrow).
Hold the bracket complete with LED auxiliary headlight (4) in position.
Install screws (5) and (6) and tighten until hand-tight.
Tighten screw (5) first and then tighten screw (6).
Tightening torques
Bracket for auxiliary headlight to fairing bracket
front with front-wheel cover, M5 x 25 2.5 Nm
Rear, M6 x 40
6 Nm
(-) Removing cover from multifunction switch
Remove screws (1).
With the clutch lever pulled slightly, work cover (2) up off the multifunction
switch.
(-) Installing cover with switch actuator
With the clutch lever pulled slightly, lower cover with switch actuator (1)
into position on the multifunction switch.
Install screws (2).
(-) Securing cable of LED auxiliary-headlight switch
Route actuating cable (1) down parallel to wiring harness (2).
Remove the original cable ties and secure actuating cable (1) to wiring
harness (2) with cable ties (arrows) installed at the same positions as the
original ties.
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Continue routing actuating cable (1) down.
(-) Releasing control unit
Open the clips (arrows) and swing up cover (1) and secure it so that it
cannot close.
Lift out control unit (2) and lay it behind the compartment.
(-) Installing relay for LED auxiliary headlights
Install relay (1) in the empty slot in relay base (2).
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(-) Securing control unit
Install control unit (2).
Lower cover (1) and engage the clips (arrows).
(-) Installing wiring-harness adapter kit for LED auxiliary
headlights
Measure the length of the LED wiring-harness adapter kit and cut off this
length with the plug from the auxiliary-headlight cables.
Use cable-stripping pliers (No. 61 9 043) to strip all the cut ends of the
auxiliary-headlight cables (detail).
Slip a shrink-fit hose (1) onto each of the wires of the LED wiring-harness
adapter kit.
Seat the stripped ends of the auxiliary-headlight cables in the push-in
connectors of the LED wiring-harness set.
The crimp connectors always have to be crimped on to both the insulation
and the stranded cable (detail).
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The cable colours of the LED wiring-harness adapter kit do not match the
original colours of the auxiliary-headlight cables.
Always connect brown to brown
LED wiring-harness adapter kit left: Brown, red/yellow to brown,
red/white auxiliary-headlight wire.
LED wiring-harness adapter kit right: Brown, red/yellow to brown,
red/green auxiliary-headlight wire.
Use crimping pliers (No. 61 0 651) and crimping head (No. 61 0 652) to
crimp on the connectors.
Slide the shrink-on hose into position over the connector and use a hot-air
gun to heat the hose.
The shrink-on hose contracts, tightens round the surface of the cable and
turns transparent. At the same time, hot glue (arrow) escapes and forms a
seal around the connection.
Wrap fibre-reinforced insulating tape (No. 61 0 631) around the cable leg.
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(-) Routing wiring harness
Seat retainer (1) on cable duct (2).
Technical data
Fuse for auxiliary
headlight
7.5 A
Route cable (3) forward along wiring harness (4) as far as the Y-branch
and clip it into clip (5).
Continue routing cable (3) up along wiring harness (4) until it reaches the
control-unit box.
Secure the cable with cable ties (arrows).
Connecting plugs for LED auxiliary headlights
Removing protective cap from plug
Remove the protective cap (arrow) from the plug.
Secure plugs (1) and (2) of the LED auxiliary headlights to the control-unit
housing.
Connect plug (1) of the LED auxiliary-headlight switch to plug (3).
Connect plug (4) to wiring-harness plug (2).
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(-) Securing cable
Secure cable with cable tie (1).
If the cables are too long use a cable tie (arrow) to secure the looped cable
to wiring harness (2).
(-) Wiring-harness routing for left LED auxiliary headlight
Route cable (1) forward along fairing carrier (2) to left LED auxiliary
headlight (3) and secure it with cable ties (arrows).
Connect plug (4) to LED auxiliary headlight (3).
Secure cable (1) with a cable tie (arrow) to bracket (5).
Use cable ties (arrows) to secure excess length (if applicable), cable
connectors (6) and rest of cable to fairing carrier (2).
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(-) Wiring-harness routing for right LED auxiliary headlight
Route cable (1) along fairing carrier (2) toward the right LED auxiliary
headlight and secure it with cable ties (arrows).
Connect plug (3) to LED auxiliary headlight (4).
Secure cable (1) with a cable tie (arrow) to bracket (5).
Use cable ties (arrows) to secure excess length (if applicable) of cable and
cable connectors (6) to fairing carrier (2).
(-) Information on disconnecting plug
If it is necessary to disconnect a plug again, insert small screwdriver (1)
into opening (2), carefully push up screwdriver (1), and pull the plug back
to disconnect.
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(-) Installing fuel tank
Push the fuel tank from behind into the rubber mounts on the frame. Make
sure that no lines, hoses or Bowden cables are trapped.
Connect breather hose (9) and overflow hose (10) at the connectors
(arrows).
Work the trim panel into position at the top wheel cover (detail).
Install screws (1) on left and right.
Place fairing bracket (8) in position (arrow).
Slightly raise the fuel tank at the rear and install screw (7).
Tightening torques
Fuel tank with bracket to front frame
M8 x 45 - 10.9
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Place fairing bracket (6) in position (arrow).
Install screw (5).
Tightening torques
Fuel tank with bracket to front frame
M8 x 45 - 10.9
19 Nm
Check the O-rings in quick-action couplings (2) for damage; replace if
necessary.
Lubricate the quick-action couplings to facilitate assembly.
Lubricant
Molykote 111
11 00 7 660 832
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 latches on the female couplings of fuel delivery lines (2) and,
applying light pressure, press the male adapter into the female coupling.
The couplings engage with an audible click.
Connect plug for fuel pump (3) and plug for fuel level sensor (4).
(-) Connecting BMW Motorrad diagnostic system to motorcycle
Note
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See the information about the BMW Motorrad diagnostic system for all
further instructions.
Connect the BMW Motorrad battery charger.
Workshop equipment
BMW Motorrad battery charger (version for Europe without GB)
BMW Motorrad battery charger (GB/AUS/NZL version)
BMW Motorrad battery charger (Japan version)
BMW Motorrad battery charger (USA/CAN version)
Begin by switching on the BMW Motorrad diagnostic system and wait
for it to power up.
The *Start Diagnosis* screen appears
From this point on, follow the instructions issued by the BMW Motorrad
diagnostic system.
(-) Retrofit with CIP (Coding, Individualisation and Programming)
Precondition
Engine is off.
Battery is fully charged and battery charger is connected.
Note
Do not attempt to perform work of any other kind on the motorcycle while
programming/coding is in progress.
Switch off all electrical consumers.
Begin by switching on the BMW Motorrad diagnostic system and wait
for it to power up.
The *Start Diagnosis* screen appears
From this point on, follow the instructions issued by the diagnostic system.
Perform diagnosis. Rectify faults, if found, before starting
programming/coding.
Start programming/coding with the CIP program and follow the instructions
issued by the diagnostic system.
Select the retrofit just completed from the range offered in CIP and step
through the rest of the procedure.
(-) Disconnecting BMW Motorrad diagnostic system from
motorcycle
Terminate the diagnosis session correctly and switch off the ignition.
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Disconnect KOMET from the motorcycle and screw the cap onto the
diagnosis plug.
Disconnect the BMW Motorrad battery charger from the motorcycle.
Finishing work
Installing intake air pipe
Installing trim panels of fuel tank
Installing right side panel
Installing right side cover
Installing left side panel
Installing left side cover
Installing front and rear seats
Adjusting LED auxiliary headlights
Final check of work performed
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