Exterior Disassembly

Control Unit Removal

BMW service manual 01 51 9 799 333 is very helpful and provides detailed instructions on fairing removal and bike disassembly down to the control unit. This instruction set provides a basic task list to follow, though presumes mechanical familiarity and confidence in disassembly of the bike.

Electrostatic discharge (ESD) mat and wrist ground strap are highly recommended.

EXTERIOR DISASSEMBLY

1. Remove left and right side wing bumper covers and silver trim panels;
2. Remove left and right side mirrors;
3. Remove both adjustable airfoils;
4. Remove both front turn signals;
5. Remove both side fairings; remove small center panel below glove box;
6. Remove upper fuel tank cover/radio/center console;
7. Remove front seat and seat mounting frame;
8. Remove fuel tank. NOTE: LESS FUEL IS BETTER at this stage of the procedure.
(K1200RS shown at right) Up to 2002 model year: Clamp off the fuel supply and return hoses, on tank side of fuel hose-barbed splice connections. These are the hoses that are towards the front of the hose splice junction, and MUST be clamped to avoid substantial fuel loss. For additional reduction in fuel spillage and loss, also clamp off the fuel return hose (upper hose) on other side of hose-splice junction.
2002 model year: Late bikes are equipped with a quick-connect fitting (not shown). Simply
depress the spring and pull fittings apart; push together to reconnect.

CONTROL UNIT REMOVAL:

1. The E-box (plastic housing where control units are stored) should be readily visible now thatthetank has been removed. Remove the three PhillipsÒ head control unit mounting screws, as shown below. The third screw is not shown in the picture due to index finger placement.

2. Pull control unit away from E-box mounting plate. Note that the electrical harness connection is permanently fixed to this baseplate. Exercise care when reinstalling to ensure that all pins are lined up within the connector housing.

NOTE: DURING NEXT STAGES OF CHIP INSTALLATION AND REPLACEMENT, IT IS CRITICAL THAT THE POTENTIAL FOR STATIC DISCHARGE BE ELIMINATED OR REDUCED. GIVEN THE MEANS BY WHICH INFORMATION IS STORED ON THE EPROM, IT IS POSSIBLE TO ERASE, CORRUPT, OR DAMAGE THE FILE FOR EITHER STOCK OR PERFORMANCE MAPS, OR CONTROL UNIT WITH ANY FORM OF ELECTROSTATIC DISCHARGE. AN ESD MAT AND WRIST GROUND STRAP ARE HIGHLY RECOMMENDED!

3. Place the control unit face up on a clean, dust-free countertop or workspace with the BMW/Bosch label facing you. Remove four T-30 Torxä, tamper-proof screws as shown.

4. Gently, and with non-magnetic slot-head screwdriver, pry the case-halves open from topside. Remember! The top has the label. NOTE: The factory silicone bead has high adhesion characteristics; two screwdrivers may be required to slowly break this bead, allowing some material to remain on both case-halves. The adhesive has a nasty tendency to pinch fingertips when the halves snap together, so BE CAREFUL!

5. Lift cover off of the control unit from left-hand side as shown. NOTE: Main printed circuit board should remain attached to the bottom cover.

6. Locate the socketed chip on the printed circuit board; this can be easily identified by the white plastic "H" shaped retaining clip, which holds the chip securely in place. This clip is shown in front of the thumb in step #5. Also note, that this chip stands taller than any of the other chips mounted on the board. Remove the H-clip using a NON-MAGNETIC thin blade screwdriver, inserted into one of the two small slots opposite each other, in the center of the clip. Gently pry the screwdriver up, away from the circuit board. This should pop the clip upwards and loose on this side. Use same procedure on the other side of the retaining clip.

7. Note installation direction of the EPROM; this is designated by a notch formed in one end. As shown here, the notch goes to the outside edge of the control unit. Serious damage could result if a chip is installed backwards, so this is a critical step.

8. Remove the chip from its socket by inserting the NON-MAGNETIC thin blade screwdriver between the short end of the chip and the socket, as shown. Pry upwards gently. Work slowly and gently pry from alternating ends of the chip. DO NOT pry the socket away from the printed circuit board! Make sure that it is the EPROM that is being removed. Avoid skin contact with the legs or pins on the chip as well, holding the silicon wafer from the short ends. Set the original program chip in or on the anti-static plastic box to avoid possibility of static charge damage.

9. Photo shows new encryption board and EPROM to be installed. First, install the encryption board into the existing, now vacant socket on the circuit board. Note that the small black dot on the left-hand edge of the encryption board (with KEY 130 or KEY 101 legible at lower RH corner) will correspond to the notch orienting the pins to their correct addresses. Partially install the far row of legs or pins into the socket. Use thumbs and index fingers to gently compress and align the near side row of pins into the relevant sockets. Exercise caution to avoid bending the pins! Carefully inspect the alignment of the pins to their corresponding sockets. Only when certain of correct alignment, gently press the encryption board downward and into place. Avoid excessive circuit board deflection. Follow same procedure for installation of performance chip into the encryption board.

10. Store the existing stock EPROM in the black plastic box that the performance EPROM was shipped inside to avoid accidental erasure.

11. Reassemble control unit in reverse order. NOTE: The H clip will not be reinstalled. Also, run a thin bead of clear RTV silicone over the existing sealer. This will prevent moisture intrusion into the control unit.

12. Reinstall control unit, fuel tank, and remaining fairing trim pieces.

©All images copyright Rhine West Performance, Inc. 2002