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BMW K1200RS 2002 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: K1200RS Year: 2002 Vehicle Type: Motorcycle Generation Generation Code: K589 (pre-facelift) Codes Engine Code: K589 👋 Introduction Market Position Segment: Sport Touring Motorcycle...
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Type: Motorcycle
Vendor:
Sku: 377638
BMW K1200RS 2002 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
K1200RS
Year:
2002
Vehicle Type:
Motorcycle
Generation
Generation Code:
K589 (pre-facelift)
Codes
Engine Code:
K589
👋 Introduction
Market Position
Segment:
Sport Touring Motorcycle
Target Audience:
BMW owners, independent motorcycle repair shops, serious enthusiasts undertaking their own maintenance and repairs.
Competitive Analysis
Key Competitors:
Honda VFR800, Yamaha FJR1300, Kawasaki Concours 14 (later models), Ducati ST4.
Key Features
Vehicle Usp:
BMW's signature blend of sportbike performance and long-distance touring comfort, with shaft drive reliability.
Manual Value Proposition:
Provides definitive factory-level knowledge, enabling accurate diagnostics, efficient repairs, and proper maintenance, saving significant costs compared to dealership servicing.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Workshop Service & Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics, Reassembly, Electrical Schematics
Page Count
Estimated Pages:
500+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Ignition System, Exhaust System, Transmission, Drive Train
Chassis:
Frame, Suspension (Front & Rear), Steering, Brakes (ABS included), Wheels, Tires
Electrical:
Battery, Charging System, Starting System, Lighting, Instrumentation, ECU, Sensor Diagnostics, Wiring Harnesses
Bodywork:
Fairings, Body Panels, Seat, Storage, Controls
Procedures Included
Routine Maintenance:
Oil Changes, Filter Replacements, Spark Plug Service, Chain/Belt Adjustment (if applicable, K1200RS is shaft drive), Brake Fluid Flush, Coolant Flush
Major Repairs:
Engine Overhaul, Transmission Rebuild, Suspension Overhaul, Brake System Bleeding/Component Replacement, Electrical System Troubleshooting
Diagnostics:
Troubleshooting charts, Fault code interpretation (OBD/Diagnostic tools), Component testing procedures
Technical Depth
Depth:
Comprehensive, covering everything from basic fluid checks to full engine rebuilds and complex electrical diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable for quick access to information
Print Quality
Printability:
High-resolution, suitable for printing individual pages or the entire manual
Binding Type
Binding Recommendation:
Printable format allows for professional binding (e.g., comb, spiral, or hardback) for workshop durability
Paper Type
Paper Recommendation:
Glossy or heavier stock paper recommended for workshop use to withstand grease and moisture
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline Four-Cylinder, Four-Stroke
Displacement:
1171 cc (71.6 cu in)
Bore X Stroke:
79 mm x 59 mm
Compression Ratio:
11.5:1
Valve Train:
DOHC, 4 Valves per Cylinder
Performance
Horsepower Hp:
110 hp @ 7500 rpm
Torque Lb-Ft:
82 lb-ft @ 6000 rpm
Fuel System
Fuel Delivery:
Bosch Motronic MA 2.4 Fuel Injection (Sequential)
Fuel Type:
Unleaded Premium Gasoline (RON 95/98)
Fuel Capacity:
24 Liters (6.3 US gal)
🔧 Transmission
Standard
Type:
6-Speed Manual
Features
Drive Type:
Shaft Drive
Clutch Type:
Wet Multi-plate Clutch
Final Drive Ratio:
2.81:1 (Typical, verify with manual)
📐 Dimensions
Exterior
Length:
2,200 mm (86.6 in)
Width:
920 mm (36.2 in) (including mirrors)
Height:
1,350 mm (53.1 in) (seat height adjustable)
Weights
Dry Weight:
244 kg (538 lbs)
Wet Weight:
267 kg (589 lbs)
Max Payload:
424 kg (935 lbs)
🛡️ Safety Features
Ratings
Crash Test Rating:
N/A (Motorcycle specific ratings not standardized like cars)
Active Features
ABS:
BMW Motorrad ABS (Integral ABS II for this generation)
Braking System Front:
Dual 320 mm Discs, 4-Piston Calipers
Braking System Rear:
Single 265 mm Disc, 2-Piston Caliper
Passive Features
Lighting:
Halogen Headlight, LED Taillight, Turn Signals
Frame Construction:
Aluminum Composite Trellis Frame
💡 Technology Features
Infotainment
Instrumentation:
Analog Tachometer, Digital Speedometer, Multi-function LCD Display (Fuel Level, Gear Indicator, Odometer, Trip Meters, Clock, Temperature)
Driver Assistance
ABS System:
Integral ABS II (Combined braking system linked to lever actuation)
Connectivity
Diagnostic Interface:
BMW 16-pin diagnostic connector for use with BMW diagnostic tools (e.g., GT1, DIS).
Engine Management
ECU System:
Bosch Motronic MA 2.4 with integrated ignition and fuel control.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km or annually (refer to manual for exact mileage)
Major Service Interval:
Typically at 20,000 km and 40,000 km, involving valve clearance checks, fluid flushes, etc.
Fluid Specifications
Engine Oil Type:
SAE 15W-50 Synthetic Motorcycle Oil (API SG or higher, JASO MA compliant) - Confirm with manual.
Engine Oil Capacity:
Approx. 4.0 liters (4.2 US qt) with filter change - Confirm with manual.
Coolant Type:
BMW approved Ethylene Glycol based coolant (e.g., BMW Motorrad Coolant)
Brake Fluid Type:
DOT 4
Final Drive Oil Type:
SAE 75W-90 Synthetic Gear Oil
Known Issues
Common Wear Items:
Clutch wear, ABS sensor reliability, fuel pump, regulator/rectifier, exhaust header corrosion (especially early models).
Electrical Gremlins:
Can be susceptible to minor electrical glitches if wiring is compromised or grounds are dirty, manual is crucial for diagnosis.
Preventative Maintenance
Key Checks:
Regular inspection of the shaft drive boot, electrical connections, and ABS system is recommended.
📚 Vehicle History
Brand Heritage
Heritage Overview:
BMW Motorrad, known for engineering excellence, pioneering features like ABS and shaft drive on motorcycles.
Model Evolution
K Series Introduction:
The K series debuted in the early 1980s with the K100, featuring a transverse inline-four engine mounted longitudinally, a revolutionary design.
K1200Rs Introduction:
The K1200RS was introduced in 1997, evolving from the K1100LT and K1100RS, offering increased performance and comfort for sport touring.
2002 Model Updates:
The 2002 model is part of the K589 generation, which received refinements over its lifespan, focusing on ergonomics and powertrain enhancement.
Production
Manufacturing Location:
Berlin, Germany
🏆 Awards & Recognition
Recognitions
Segment Acclaim:
Consistently praised for its blend of performance, comfort, and technology in the sport-touring segment during its production years.
Ratings
Owner Satisfaction:
Generally high owner satisfaction for its reliability and long-distance capability, though maintenance can be complex.
Certifications
Emissions Compliance:
Meets relevant Euro emissions standards for its model year.
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