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BMW K1200 K1200RS 2004 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: K1200RS Year: 2004 Codes Model Code: K589 👋 Introduction Market Position Segment: Sport-touring motorcycle Usp: Known for its powerful Boxer engine, sophisticated technology,...
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BMW K1200 K1200RS 2004 Workshop Repair Service ManualBMW K1200 K1200RS 2004 Workshop Repair Service ManualBMW K1200 K1200RS 2004 Workshop Repair Service ManualBMW K1200 K1200RS 2004 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
K1200RS
Year:
2004
Codes
Model Code:
K589
👋 Introduction
Market Position
Segment:
Sport-touring motorcycle
Usp:
Known for its powerful Boxer engine, sophisticated technology, and comfortable long-distance riding capabilities.
Competitive Analysis
Competitors:
Honda VFR, Yamaha FJR1300, Kawasaki GTR1400.
Key Features
Engine Layout:
Longitudinal Boxer-Four
Drive System:
Shaft drive
Braking System:
Integral ABS (optional on some earlier models, standard on later ones like 2004).
📋 Manual Details
Coverage Areas
General Coverage:
All Models, Engines, Trims, Transmissions
Page Count
Estimated Page Count:
500+
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive engine disassembly, assembly, diagnostics, and tuning for the K1200RS's Boxer engine.
Fuel System:
Detailed information on fuel injection system, fuel pump, injectors, pressure regulator, and emissions control.
Ignition System:
Coverage of ignition coils, spark plugs, ECU control, and timing adjustments.
Transmission:
Complete service and repair procedures for the gearbox, clutch, and final drive.
Suspension:
Front and rear suspension systems, including fork service, shock absorber replacement, and adjustment procedures.
Brakes:
Detailed procedures for hydraulic brake systems (ABS), including caliper service, pad replacement, fluid bleeding, and ABS unit diagnostics.
Electrical System:
Extensive coverage of wiring diagrams, component testing, battery, alternator, starter motor, lighting, and electronic control units (ECUs).
Chassis:
Frame, subframe, steering head, and related components.
Bodywork:
Fairing removal and installation, seat service, and component fitting.
Diagnostics:
Troubleshooting guides, fault codes, diagnostic procedures, and recommended test equipment.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment (if applicable), spark plug replacement, brake fluid changes, coolant checks.
Component Overhaul:
Complete engine rebuilds, transmission overhauls, suspension component refurbishment, brake caliper rebuilding.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues across all vehicle systems.
Electrical Repairs:
Wiring harness repair, sensor testing and replacement, ECU diagnostics and flashing (where applicable).
Special Tools:
Identification and usage of specialized BMW tools required for specific repair procedures.
Technical Depth
Depth:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts, covering everything from basic maintenance to complete engine rebuilds and advanced diagnostics.
Accuracy:
Based on original BMW factory service data, ensuring high accuracy and adherence to specifications.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Text-searchable PDF for quick information retrieval.
Print Quality
Quality:
High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Completeness
Completeness:
Highly comprehensive, covering all aspects of service, maintenance, repair, and troubleshooting for the specified model year.
⚙️ Engine Specifications
Primary Engine
Engine Type:
1171cc, Four-stroke, Boxer-Four cylinder, DOHC, 4 valves per cylinder
Bore X Stroke:
98 mm x 79 mm
Compression Ratio:
11.5:1
Performance
Horsepower:
110 hp (81 kW) @ 8200 rpm (approximate)
Torque:
117 Nm (86 lb-ft) @ 6000 rpm (approximate)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - Bosch Motronic MA 2.4
Fuel Type:
Unleaded Premium (95 RON recommended)
Cooling System
Cooling Method:
Oil and Air cooled
Lubrication
Oil Type:
SAE 20W-40 or 10W-40 motorcycle-specific oil
Oil Capacity:
Approx. 4.0 liters (4.2 US quarts) with filter change
🔧 Transmission
Standard
Type:
6-speed sequential manual gearbox
Features
Drive:
Enclosed shaft drive
Clutch:
Hydraulically operated, multi-plate wet clutch
Fluid Specifications
Gearbox Oil:
SAE 75W/90 GL-5 gear oil
Fluid Capacities
Gearbox Oil Capacity:
Approx. 1.7 liters (1.8 US quarts)
📐 Dimensions
Exterior
Length:
Approx. 2230 mm (87.8 in)
Width:
Approx. 925 mm (36.4 in) (at handlebars)
Height:
Approx. 1330 mm (52.4 in) (seat height adjustable)
Weights
Dry Weight:
Approx. 243 kg (536 lbs)
Wet Weight:
Approx. 262 kg (578 lbs)
Fuel Capacity
Tank Capacity:
21 liters (5.5 US gallons), including a 4-liter reserve
Wheelbase
Wheelbase:
Approx. 1505 mm (59.25 in)
🛡️ Safety Features
Ratings
ABS:
Integral ABS (BMW Motorrad ABS II) available as standard or optional depending on market/production date.
Active Features
Braking:
Linked braking system with ABS; front and rear brakes are activated simultaneously when either brake lever is pulled.
Passive Features
Lighting:
Halogen headlight with dual bulbs for improved illumination.
💡 Technology Features
Infotainment
Instrumentation:
Comprehensive analog and digital instrument cluster including speedometer, tachometer, fuel gauge, gear indicator, and warning lights.
Driver Assistance
ABS:
BMW Integral ABS II - a sophisticated, linked braking system.
Connectivity
Diagnostics Port:
OBD-II style diagnostic connector for electronic fault finding and data retrieval using appropriate BMW diagnostic tools.
Lighting
Headlight System:
Dual halogen headlight system for enhanced visibility, often with adjustable beam height.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,000 miles) or annually, whichever comes first.
Major Service Interval:
Every 20,000 km (12,000 miles) for valve clearance checks, spark plug replacement, and fluid changes.
Fluid Specifications
Brake Fluid:
DOT 4
Coolant:
BMW Motorrad Coolant (ethylene glycol based, with corrosion inhibitors) - typically a 50/50 mix with distilled water.
Final Drive Oil:
SAE 80W/90 GL-5 gear oil
Known Issues
Fuel Pump:
Occasional premature failure of the fuel pump assembly. Manual covers diagnostic procedures.
ABS Sensors:
ABS sensor ring damage or failure can occur. Manual details troubleshooting and replacement.
Clutch Actuator:
Potential for leaks or sticking in the clutch slave cylinder. Manual provides overhaul instructions.
Rear Shock ABSorber:
Wear and tear leading to reduced damping performance over time. Manual details replacement procedures.
📚 Vehicle History
Brand Heritage
Heritage:
BMW Motorrad boasts a long and distinguished history, renowned for engineering excellence, reliability, and innovation in motorcycle design.
Model Evolution
K Series Evolution:
The K1200RS is part of BMW's K-Series, which originally featured transverse inline-fours, but evolved to the longitudinal Boxer-Four configuration for enhanced weight distribution and handling.
Production
Production Years:
1997-2004 (for the K589 model generation)
Manufacturing Location:
Berlin, Germany
🏆 Awards & Recognition
Recognitions
Reputation:
Generally praised for its comfort, performance, and build quality in the sport-touring category during its production run.
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