BMW R1200RT Bulkhead Fitting Installation

One by the header below.

One by the header.

These 3 screws.

Left side panel screw near seat pan.

Left panel screw.

Front side panel screw.

side panel thumb lock

left panel two front bottom screws

left panel two screws under power outlet. Only one needs to come out but I forget which one.

Left panel top right screw

BMW RT center panel upper screws

The following photos show how to remove the left side panel on the BMW R1200RT.

The outside of the finished job.

Here is the inside view. Note the trash to be cleaned.

This is our custom bulkhead fitting modified for an O-Ring. With non-metallic tanks the O-ring needs to go on the INSIDE. Metallic tanks have the O-ring on the OUTSIDE. Ignore the later picture showing a sealant, we no longer recommend use of any gasket material.

Make this hole. Afterwards, use a sharp knife to clean up the burrs. Then make sure you clean all the crap out of the tank you made.

Same location just a differnt angle on the shot.

This nice flat spot just above the left cyclinder is where the fitting goes.

No need to remove these hoses. The only reason this comes off is so you can reach inside to tighten the fitting.

With the side panel off the fuel pump assembly is exposed. Remove the hoses and plugs. Unscrew the retaining ring. You don't need the BMW special tool. You can don some gloves and might be able to untwist it. If that fails some gentle hammering with a soft punch (aluminum, brass, or wood) will get this started and then it comes off easily.

Here's how everything is connected BEFORE you start. :-)

Notice I didn't completely remove the side fairing, I just slide it forward. I didn't want to deal with all that wiring.

You need to remove the fuel pump assembly to gain access to the inside of the tank.

This is the final photo showing where the fitting is located.