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BMW R1200GS/GS Adventure (K25) 2004 to 2012 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: R1200GS Model Variant: GS Adventure Chassis Code: K25 Generation Production Years: 2004-2012 👋 Introduction Market Position Segment: Adventure Touring Motorcycle Reputation: Benchmark in...
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BMW R1200GS/GS Adventure (K25) 2004 to 2012 Service Repair ManualBMW R1200GS/GS Adventure (K25) 2004 to 2012 Service Repair ManualBMW R1200GS/GS Adventure (K25) 2004 to 2012 Service Repair ManualBMW R1200GS/GS Adventure (K25) 2004 to 2012 Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
R1200GS
Model Variant:
GS Adventure
Chassis Code:
K25
Generation
Production Years:
2004-2012
👋 Introduction
Market Position
Segment:
Adventure Touring Motorcycle
Reputation:
Benchmark in the adventure touring segment, known for versatility, durability, and capability across diverse terrain.
Competitive Analysis
Key Competitors:
KTM 990 Adventure, Honda Africa Twin (earlier models), Triumph Tiger 1050/1200, Yamaha Super Ténéré.
Key Features
Design Philosophy:
Purpose-built for long-distance touring and off-road capability, balancing comfort, performance, and ruggedness.
Engine Architecture:
Air/oil-cooled, four-stroke boxer-twin engine.
Chassis Features:
Telelever front suspension, Paralever rear suspension, robust frame construction.
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive Service and Repair
Page Count
Estimated Pages:
700+
Manual Type
Type:
Workshop Manual / Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine disassembly, assembly, tuning, valve clearance, timing chain, oil pump, lubrication system, cooling system.
Fuel System:
Fuel injection system (EFI), throttle body, fuel pump, fuel injectors, fuel lines, fuel tank, evaporative emissions control (EVAP).
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, oxygen sensors (lambda sensors).
Transmission:
Gearbox (6-speed sequential), clutch operation, gear shift mechanism, final drive (shaft drive), driveshaft, universal joints, final drive housing.
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starter motor, ignition system, lighting system (headlight, taillight, turn signals, brake lights), horn, instrumentation, wiring diagrams.
Electronics:
Engine control unit (ECU), ABS (Anti-lock Braking System), ASC (Automatic Stability Control) / DTC (Dynamic Traction Control) operation and diagnostics, tire pressure monitoring (TPMS), immobilizer system, diagnostic connectors and procedures.
Suspension:
Front telelever suspension, rear paralever suspension, shock absorbers, springs, fork seals, bushings, adjustments.
Brakes:
Front and rear disc brakes, brake calipers, master cylinders, brake lines, brake fluid, ABS system components, brake pad replacement, brake bleeding procedures.
Wheels Tires:
Wheel bearing replacement, tire mounting and balancing, recommended tire sizes, wheel specifications.
Frame Chassis:
Frame construction, subframe, steering head bearings, pivot bearings.
Bodywork:
Fairings, fuel tank, seat, fenders, luggage rack, handguards, wind deflector, removal and installation procedures.
Procedures Included
Scheduled Maintenance:
Detailed service intervals for oil changes, filter replacements, valve checks, brake fluid changes, etc.
Troubleshooting:
Diagnostic flowcharts, common problems and solutions, fault code interpretation.
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly.
Diagnostic Procedures:
Using BMW diagnostic tools (e.g., GT1, DIS, ISTA/P), reading fault codes, sensor data analysis.
Adjustment Procedures:
Throttle cable adjustment, clutch lever adjustment, suspension preload adjustment.
Wiring Diagrams:
Complete, high-resolution electrical system schematics for all major components and systems.
Technical Depth
Depth:
Expert-level; suitable for professional technicians and advanced DIY mechanics. Covers full rebuilds and complex diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution scans, clear text, sharp images and diagrams.
Binding Type
Binding:
N/A (Digital)
Paper Type
Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Configuration:
Horizontally opposed twin-cylinder (Boxer)
Displacement:
1170 cc (1.17 Liters)
Bore X Stroke:
101 mm x 73 mm
Compression Ratio:
12.0:1
Valve Train:
DOHC (Double OverHead Camshafts), 4 valves per cylinder, driven by two camshafts via timing chains.
Cooling System:
Air/oil cooling
Performance
Horsepower:
105 hp (77 kW) @ 7500 rpm
Torque:
115 Nm (85 lb-ft) @ 5750 rpm
Fuel System
Induction:
Electronic Fuel Injection (EFI), Bosch Motronic MED17.2
Fuel Type:
Unleaded premium gasoline (95 RON / 91 AKI)
Lubrication
Oil Type:
API SJ/SL, SAE 20W-50, BMW Motorrad Approved Motorcycle Oil.
🔧 Transmission
Standard
Type:
6-speed manual constant mesh gearbox
Clutch:
Single dry plate, hydraulically actuated
Final Drive:
Shaft drive
Features
Gear Ratios:
1st: 2.375, 2nd: 1.750, 3rd: 1.310, 4th: 1.077, 5th: 0.926, 6th: 0.807
Final Drive Ratio:
3.091 (34/11 teeth)
Fluid Type
Gearbox Oil:
SAE 75W-90 GL-5 API Gear Oil (e.g., BMW Hypoid Gear Oil) - Capacity: approx. 1.0 Litre.
Final Drive Oil:
SAE 75W-90 GL-5 API Gear Oil (e.g., BMW Hypoid Gear Oil) - Capacity: approx. 0.25 Litre.
📐 Dimensions
Exterior
Length:
2230 mm (87.8 in) - GS; 2270 mm (89.4 in) - GS Adventure
Width:
905 mm (35.6 in) - GS; 980 mm (38.6 in) - GS Adventure
Height:
1420 mm (55.9 in) - GS; 1470 mm (57.9 in) - GS Adventure (adjustable windshield)
Wheelbase:
1507 mm (59.3 in)
Seat Height:
850 mm (33.5 in) / 870 mm (34.3 in) - GS (adjustable); 880 mm (34.6 in) / 900 mm (35.4 in) - GS Adventure (adjustable)
Weights
Dry Weight:
229 kg (505 lbs) - GS; 244 kg (538 lbs) - GS Adventure
Gross Vehicle Weight Rating:
465 kg (1025 lbs)
Cargo
Fuel Tank Capacity:
20 Liters (5.3 gal) - GS; 33 Liters (8.7 gal) - GS Adventure
🛡️ Safety Features
Ratings
Safety Features:
Integral ABS (Anti-lock Braking System) - Optional on some models/markets, ASC (Automatic Stability Control) / DTC (Dynamic Traction Control) - Optional on some models/markets.
Active Features
ABS:
Optional on early models, integrated with braking system, can be deactivated for off-road use.
Traction Control:
ASC/DTC available on later models, enhances grip and stability.
Passive Features
Lighting:
Halogen headlight, LED taillight, multi-reflector turn signals.
Ergonomics:
Designed for rider comfort and control during long-distance and varied terrain riding.
💡 Technology Features
Infotainment
Instrumentation:
Analog tachometer, digital speedometer, LCD multi-function display showing gear indicator, fuel level, trip meters, ambient temperature, clock, service reminders, and diagnostic information.
Driver Assistance
Esa Electronic Suspension Adjustment:
Optional feature allowing riders to electronically adjust suspension preload and damping (Comfort, Normal, Sport) via handlebar controls.
Heated Grips:
Standard or optional depending on trim/year.
On Board Computer:
Provides detailed trip information, average fuel consumption, current fuel consumption, range, and outside temperature.
Connectivity
Diagnostic Interface:
CAN-bus system with OBD-II compatible diagnostic connector for advanced fault code reading and system diagnostics.
🔧 Maintenance
Service Intervals
Oil Change:
Every 10,000 km (6,200 miles) or 12 months.
Valve Check:
Every 20,000 km (12,400 miles).
Brake Fluid Change:
Every 2 years.
Final Drive Oil Change:
Every 20,000 km (12,400 miles).
Spark Plug Replacement:
Every 40,000 km (24,800 miles).
Fluid Specifications
Engine Oil:
BMW Motorrad Approved Motorcycle Oil, API SJ/SL, SAE 20W-50. Capacity: 3.0 Liters (with filter).
Brake Fluid:
DOT 4.
Coolant:
BMW Motorrad Coolant (G48 ethylene glycol-based) or equivalent, mixed 50/50 with distilled water. Capacity: approx. 2.2 Liters.
Known Issues
Common Complaints:
Spline wear on driveshaft/final drive (requires lubrication), potential for clutch slave cylinder leaks, paralever seal leaks, electronic glitches (especially with early CAN-bus systems).
Preventative Measures:
Regular lubrication of driveshaft splines, monitoring for fluid leaks, proper charging system maintenance.
📚 Vehicle History
Brand Heritage
Bmw Motorcycle Legacy:
BMW Motorrad has a long and storied history in motorcycle manufacturing, dating back to 1923, with a particular strength in boxer-twin engines and touring motorcycles.
Model Evolution
R Series Adventure:
The R1200GS builds upon the legacy of the R80G/S and R1150GS, which established the 'adventure' motorcycle category. The R1200GS (K25) represented a significant technological advancement over its predecessor.
Generation Changes:
This K25 generation saw the introduction of a more powerful engine, electronic fuel injection, CAN-bus electronics, and optional electronic suspension adjustment (ESA) and ABS/ASC in later iterations.
Production
Manufacturing Location:
Berlin, Germany (BMW Motorrad plant)
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Consistently praised by motorcycle journalists and riders for its versatility, comfort, and capability across a wide range of riding conditions. Often cited as a category-defining motorcycle.
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