BMW K1200RS Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: K1200RS Codes Engine Family Code: K589 👋 Introduction Market Position Segment: Sport Touring Motorcycle Target Audience: Long-distance touring riders, performance-oriented motorcyclists seeking comfort...

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Mots clés: BMW Cars K1200RS Misc Motorcycle

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Description

🏷️ Basic Information

Identification

Make:

Model:

K1200RS

Codes

Engine Family Code:

👋 Introduction

Market Position

Segment:

Sport Touring Motorcycle

Target Audience:

Long-distance touring riders, performance-oriented motorcyclists seeking comfort and capability.

Competitive Analysis

Key Competitors:

Honda VFR800/VFR1200, Kawasaki GTR1400, Yamaha FJR1300, Suzuki GSX1250FA.

Key Features

Engine Type:

Liquid-cooled, DOHC, inline four-cylinder engine with four valves per cylinder.

Suspension Type:

BMW's innovative Duolever front and Paralever rear suspension systems for precise handling.

Braking System:

Integral ABS (Anti-lock Braking System) for enhanced safety and control.

Ergonomics:

Comfortable rider triangle for long-distance touring, adjustable windscreen, heated grips.

📋 Manual Details

Coverage Areas

Model Years Covered:

1997-2005

Region Coverage:

Global (all model variations)

Page Count

Estimated Page Count:

1200+

Manual Type

Manual Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full disassembly, inspection, repair, and assembly of the 1171cc DOHC inline-four engine.

Fuel System:

Fuel injection system (EFI), throttle bodies, fuel pump, injectors, pressure regulator, diagnostics.

Ignition System:

Ignition control module (ICM), spark plugs, ignition coils, timing.

Cooling System:

Radiator, cooling fan, thermostat, coolant circuits, bleeding procedures.

Exhaust System:

Mufflers, catalytic converter (if applicable), exhaust manifold, sensor diagnostics.

Transmission Clutch:

Six-speed gearbox, clutch operation, master cylinder, slave cylinder, hydraulic fluid specifications, gearbox oil.

Drive Shaft:

Shaft drive system, universal joints, final drive housing, driveshaft maintenance.

Front Suspension:

Duolever front suspension system, fork assembly, steering head bearings, adjustment procedures.

Rear Suspension:

Paralever rear suspension, monoshock absorber, linkage bearings, adjustment procedures.

Braking System:

Integral ABS braking system (front and rear), brake fluid type (DOT 4), caliper servicing, disc replacement, hydraulic unit testing.

Wheels Tires:

Wheel bearing replacement, tire pressure specifications, wheel balance.

Electrical System:

Battery, charging system (alternator, regulator), lighting, starter motor, wiring diagrams, fuses, relays.

Instrumentation Controls:

Dashboard instruments, switchgear, handlebar controls, throttle grip, clutch lever.

Bodywork Fairings:

Fairing removal and installation, seat assembly, tank removal, cosmetic repairs, panel alignment.

Chassis Frame:

Frame inspection, torque specifications for fasteners, component mounting.

Diagnostics:

On-board diagnostics (OBD), fault codes, troubleshooting procedures for all electronic systems.

Procedures Included

Routine Maintenance:

Oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain/driveshaft adjustment, brake pad inspection.

Major Repairs:

Engine rebuild, transmission overhaul, suspension component replacement, ABS system bleeding and component replacement.

Troubleshooting:

Step-by-step diagnostic guides for common and uncommon issues, fault tree analysis.

Electrical Diagnostics:

Wiring diagrams interpretation, multimeter usage for voltage, resistance, and continuity testing, component testing.

Special Tool Usage:

Instructions and specifications for specialized BMW tools required for specific procedures.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from basic fluid checks to complete engine and transmission overhauls.

Diagnostic Level:

Advanced diagnostics for electronic control units (ECU) and sensor systems.

Repair Level:

Detailed repair procedures with torque specifications, clearances, and assembly sequences.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content for quick information retrieval.

Print Quality

Image Resolution:

High-resolution images, diagrams, and schematics for clarity.

Binding Type

Binding For Digital:

N/A (Digital)

Paper Type

Paper Type For Digital:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder, 4-stroke, DOHC, 16 valves

Displacement:

1171 cc (71.6 cu in)

Bore X Stroke:

77.6 mm x 64 mm (3.06 in x 2.52 in)

Compression Ratio:

12.0:1

Performance

Horsepower Peak:

130 hp @ 8750 rpm (approximate)

Torque Peak:

115 Nm (85 lb-ft) @ 6750 rpm (approximate)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), Bosch Motronic MA 2.4

Fuel Type:

Unleaded Premium (95 RON / 91 AKI)

Lubrication

Oil Type:

SAE 5W-40 Synthetic Motorcycle Oil (API SG or higher, JASO MA compliant)

Oil Capacity W Filter:

Approx. 4.0 liters (4.2 US qt)

🔧 Transmission

Standard

Transmission Type:

Constant-mesh 6-speed sequential gearbox

Clutch Type:

Hydraulically operated, multi-plate wet clutch

Optional

Optional Transmission:

N/A (Manual transmission standard)

Features

Final Drive:

Shaft drive

Gearbox Oil Type:

BMW Gear Oil SAE 75W/90 (API GL-5)

📐 Dimensions

Exterior

Length:

Approx. 2220 mm (87.4 in)

Width At Handlebars:

Approx. 915 mm (36.0 in)

Height To Seat:

Approx. 800 mm (31.5 in)

Weights

Dry Weight:

Approx. 244 kg (538 lbs)

Gross Vehicle Weight Rating:

Approx. 470 kg (1036 lbs)

🛡️ Safety Features

Ratings

ABS System:

Integral ABS II (standard)

Active Features

Lighting:

Halogen headlight, LED taillight, integrated turn signals.

Braking Features:

Dual 320 mm front discs with 4-piston calipers, Single 265 mm rear disc with 2-piston caliper, linked braking.

Passive Features

Instrumentation:

Comprehensive dashboard with analog tachometer and speedometer, digital multi-function display.

💡 Technology Features

Infotainment

Instrument Cluster:

Digital odometer, trip meters, gear indicator, fuel gauge, engine temperature, clock, warning lights, and diagnostic indicators.

Driver Assistance

ABS System Details:

Integral ABS II provides linked braking and anti-lock protection for both wheels.

Connectivity

Diagnostics Port:

BMW's proprietary diagnostic connector for electronic fault code reading and system analysis.

Comfort Features

Heated Grips:

Standard on most models, providing variable heat settings.

Windscreen:

Electrically adjustable windscreen for optimal wind protection.

🔧 Maintenance

Service Intervals

First Service:

1,000 km (600 miles) or 6 months, whichever comes first.

Subsequent Services:

Every 10,000 km (6,000 miles) or 12 months.

Major Engine Checks:

Valve clearance checks typically recommended every 20,000 - 30,000 km (12,000 - 18,000 miles).

Fluid Specifications

Engine Oil Filter Part Number:

BMW Part No. 11 42 1 457 403 (e.g., Mahle OC 91/4, KN-160)

Brake Fluid Specification:

DOT 4 (ISO 4925 Class 4 / FMVSS 116 DOT 4)

Coolant Specification:

BMW Coolant (G48 ethylene glycol based) or equivalent meeting BMW specifications.

Known Issues

Final Drive Splines:

Occasional wear on final drive splines requires regular greasing.

Stator Failure:

Potential for stator failure in some models, affecting charging system output.

ABS Pump Issues:

Rare instances of ABS hydraulic unit (pump) failure, often related to fluid contamination or age.

Electrical Connectors:

Corrosion or poor contact in electrical connectors, particularly in areas exposed to weather.

📚 Vehicle History

Brand Heritage

Bmw Motorrad Legacy:

BMW Motorrad boasts a long history of engineering excellence and innovation in motorcycle design and manufacturing since its inception in 1923.

Model Evolution

K Series Origin:

The K1200RS is part of BMW's K-series, which debuted in the early 1980s with the distinctive transverse-mounted, shaft-driven inline-four 'K-engine'. The RS designation typically signifies a more sport-oriented touring machine.

K1200Rs Development:

The K1200RS evolved from earlier K-series models, focusing on increased performance, improved aerodynamics, and advanced suspension technology. It was a flagship model for BMW's sport-touring segment.

Production

Production Years:

1997 - 2005

Manufacturing Location:

Berlin, Germany (BMW Motorrad plant)

🏆 Awards & Recognition

Recognitions

Magazine Reviews:

Consistently praised in motorcycle publications for its performance, handling, and touring comfort, often receiving high marks in comparison tests.

Ratings

Reliability Reputation:

Generally considered a reliable and robust motorcycle with proper maintenance.

Certifications

Emissions Standards:

Compliant with applicable emissions standards for its production era.