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BMW K1200 K1200RS 2002 All Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: K1200RS Year: 2002 Codes Model Code: K589 👋 Introduction Market Position Segment: Sport-Touring Motorcycle Target Audience: Discerning riders seeking comfort, performance, and long-distance...
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BMW K1200 K1200RS 2002 All Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
K1200RS
Year:
2002
Codes
Model Code:
K589
👋 Introduction
Market Position
Segment:
Sport-Touring Motorcycle
Target Audience:
Discerning riders seeking comfort, performance, and long-distance capability
Competitive Analysis
Key Competitors:
Honda ST1100, Kawasaki GTR1000, Yamaha FJR1300
Key Features
Design Philosophy:
BMW's signature engineering, focus on rider ergonomics, integrated luggage, and robust performance
Value Proposition:
Comprehensive resource for owners and technicians to maintain and repair the K1200RS to factory standards
📋 Manual Details
Coverage Areas
Manual Type:
Service & Repair Manual
Language:
English
Format:
Digital Download (PDF)
Page Count
Estimated Pages:
300+
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, fuel injection system, ignition system, cooling system, lubrication system
Transmission:
Gearbox inspection and repair, clutch assembly, final drive, shaft drive maintenance
Chassis:
Frame inspection, front suspension (Paralever), rear suspension (Duolever), steering system, wheel bearings
Brakes:
ABS system diagnostics and repair, brake fluid replacement, caliper overhaul, rotor inspection, brake line maintenance
Electrical:
Wiring diagrams, battery system, charging system, starter motor, lighting system, instrument cluster, ECU diagnostics
Bodywork:
Fairing removal and installation, seat assembly, fuel tank maintenance, body panel repair
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, brake pad replacement, valve clearance checks
Troubleshooting:
Diagnostic procedures for common and uncommon faults, fault code interpretation, symptom-based troubleshooting guides
Repair:
Step-by-step repair instructions for all major mechanical and electrical components, torque specifications for all fasteners
Disassembly Assembly:
Detailed procedures for removing and reinstalling all major parts and sub-assemblies
Technical Depth
Diagnostic Capability:
Advanced diagnostic procedures including ECU parameter checks and sensor data interpretation
Rebuild Procedures:
Comprehensive guides for engine and transmission rebuilding
Special Tools:
Identification and usage instructions for specialized BMW tools required for specific procedures
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Searchability:
Text-searchable PDF for quick information retrieval
Print Quality
Resolution:
High-resolution, suitable for printing
Binding Type
Binding Method:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, four-stroke
Displacement:
1171 cc
Bore X Stroke:
79 mm x 59 mm
Compression Ratio:
10.2:1
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower:
110 hp @ 8500 rpm (claimed)
Torque:
115 Nm (85 lb-ft) @ 6750 rpm (claimed)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Bosch Motronic MA 2.4
Fuel Type:
Unleaded Premium Gasoline (95 RON / 91 AKI)
Lubrication
Oil Capacity:
4.0 Liters (4.2 US quarts) with filter change
Oil Type:
SAE 20W-40 or SAE 15W-50 (API SG or higher)
Cooling System
Cooling Method:
Liquid-cooled
Coolant Type:
BMW approved coolant mixture (50% ethylene glycol / 50% distilled water)
🔧 Transmission
Standard
Transmission Type:
6-speed manual
Features
Clutch:
Hydraulically operated, multi-plate wet clutch
Final Drive:
Shaft drive
Transmission Fluid:
Hypoid gear oil, API GL-5, SAE 90
📐 Dimensions
Exterior
Length:
2220 mm (87.4 in)
Width:
940 mm (37.0 in) (at handlebars)
Height:
1430 mm (56.3 in) (at handlebars)
Wheelbase:
1509 mm (59.4 in)
Weights
Dry Weight:
243 kg (536 lbs)
Wet Weight:
263 kg (580 lbs) (approx.)
Payload Capacity:
230 kg (507 lbs) (including rider and luggage)
Cargo
Luggage Capacity:
Integrated saddlebags, optional top case
🛡️ Safety Features
Ratings
Braking System:
BMW Motorrad Integral ABS (optional)
Active Features
Lighting:
Halogen headlight, LED taillight, integrated turn signals
Handling:
Stable chassis geometry, advanced suspension systems (Duolever/Paralever)
Passive Features
Rider Comfort:
Adjustable windscreen, ergonomic seating position, heated grips
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer and speedometer, digital display for gear indicator, clock, trip meters, and warning lights.
Audio System:
Optional integrated radio/cassette or CD player with handlebar controls and speakers.
Driver Assistance
ABS:
BMW Motorrad Integral ABS (available as an option), providing linked braking for enhanced safety.
Connectivity
Diagnostic Port:
OBD-II compatible diagnostic port for electronic fault diagnosis.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,000 miles) or annually
Major Service Interval:
Every 20,000 km (12,000 miles) for valve checks, fuel system inspection, etc.
Brake Fluid Change:
Every 2 years
Fluid Specifications
Fork Oil Type:
SAE 7.5W or BMW approved fork oil
Coolant Type:
BMW approved coolant mixture (50% ethylene glycol / 50% distilled water)
Brake Fluid Type:
DOT 4 (for ABS and non-ABS systems)
Known Issues
Fuel Pump Reliability:
Some early models experienced fuel pump failures; later revisions improved reliability.
ABS Modulator Issues:
Potential for ABS modulator failures in high-mileage or neglected units. Regular bleeding is crucial.
Clutch Slave Cylinder:
Occasional leaks from the clutch slave cylinder seal can occur.
Electrical Connector Corrosion:
Corrosion in electrical connectors, particularly in exposed areas, can lead to intermittent faults.
📚 Vehicle History
Brand Heritage
Bmw Motorcycle Division:
Founded in 1916, BMW Motorrad has a long and prestigious history in motorcycle manufacturing, known for innovation and quality.
Model Evolution
K Series Introduction:
The K-series, introduced in 1983, featured a horizontally opposed four-cylinder engine, revolutionizing BMW's motorcycle lineup.
K1200Rs Development:
The K1200RS (K589) was a successor to the K1100RS, offering increased power, improved aerodynamics, and updated chassis technology.
Production
Production Years:
1997-2004 (K589 model)
Manufacturing Location:
Berlin, Germany
🏆 Awards & Recognition
Recognitions
Motorcycle Press Reviews:
Consistently praised by motorcycle publications for its comfort, performance, and touring capability.
Ratings
Reliability Reputation:
Generally considered a reliable and durable machine when properly maintained.
Certifications
Emissions Standards:
Meets prevailing emissions standards for its model year.
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