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BMW K1200RS K1200 RS Motorcycle Complete Workshop Service Repair Manual 2001 2002 2003 2004 2005

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🏷️ Basic Information Identification Make: BMW Model: K1200RS Model Variant: K1200 RS Vehicle Type: Motorcycle Generation Generation: First Generation (K589) Codes Chassis Code: K589 👋 Introduction Market Position Segment: Sport...
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BMW K1200RS K1200 RS Motorcycle Complete Workshop Service Repair Manual 2001 2002 2003 2004 2005
🏷️ Basic Information
Identification
Make:
BMW
Model:
K1200RS
Model Variant:
K1200 RS
Vehicle Type:
Motorcycle
Generation
Generation:
First Generation (K589)
Codes
Chassis Code:
K589
👋 Introduction
Market Position
Segment:
Sport Touring Motorcycle
Target Audience:
Touring riders, sport-touring enthusiasts, riders seeking high-performance and long-distance comfort.
Competitive Analysis
Key Competitors:
Honda ST1300, Yamaha FJR1300, Kawasaki GTR1400, Triumph Sprint ST.
Key Features Vehicle
Engine Configuration:
Inline four-cylinder Boxer-twin (horizontally opposed cylinders).
Suspension Technology:
Duolever front suspension, Paralever rear swingarm with shaft drive.
Braking Technology:
Integral ABS (Anti-lock Braking System) with linked braking.
Key Features Manual
Manual Utility:
Essential for DIY maintenance, repair, and advanced troubleshooting, reducing reliance on dealerships.
Value Proposition:
Cost-effective solution for maintaining the K1200RS, providing professional-level guidance.
📋 Manual Details
Coverage Areas
Model Years Covered:
2001, 2002, 2003, 2004, 2005
Regions Covered:
Global (specifications may vary by market)
Page Count
Estimated Page Count:
500+
Manual Type
Manual Type:
Complete Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine teardown, assembly, valve adjustment, timing, fuel injection, ignition, cooling system, exhaust system, lubrication system, engine management (DME/ECU).
Drivetrain Systems:
Clutch operation and service, gearbox internal and external components, final drive (shaft drive), driveshaft maintenance, differential (if applicable, though typically not on this model).
Chassis Suspension:
Front fork (including EVO-Sport suspension system), rear shock absorber, swingarm, wheel bearings, steering head bearings, suspension adjustments.
Braking System:
Front and rear brake calipers, master cylinders, brake lines, ABS system (Integral ABS), brake pad replacement, rotor inspection, brake fluid bleeding.
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starter motor, lighting (headlights, taillights, turn signals), instrumentation, wiring diagrams, fuses, relays, ignition switch, fault diagnosis (OBD).
Bodywork Fairings:
Fairing removal and installation, seat, fuel tank, fenders, mirrors, luggage system components, cosmetic repairs.
Control Systems:
Throttle control, clutch lever, brake levers, shift lever, footpegs, handlebar assembly, cable adjustments.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, air filter cleaning/replacement, chain/driveshaft lubrication and adjustment, brake fluid replacement, coolant checks and replacement.
Troubleshooting Diagnostics:
Systematic troubleshooting guides for common and uncommon problems, diagnostic codes, electrical system fault finding, engine performance issues.
Major Repairs:
Engine overhauls, transmission repairs, suspension component replacement, ABS system servicing, electrical component replacement.
Special Tools:
Identification and usage of specialized tools required for specific procedures (e.g., torque wrenches, engine timing tools, suspension tools).
Technical Depth
Depth Of Coverage:
Comprehensive from basic rider maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures.
Wiring Diagrams:
Detailed electrical schematics for all systems, color-coded for clarity.
Torque Specifications:
Explicit torque values for all critical fasteners.
Exploded Views:
Detailed exploded diagrams of all major components and sub-assemblies.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Searchability:
Searchable text within the PDF for quick information retrieval.
Print Quality
Image Resolution:
High-resolution images and diagrams suitable for printing.
Binding Type
Binding Type Digital:
N/A (Digital Download)
Paper Type
Paper Type Digital:
N/A (Digital Download)
Accessibility
Device Compatibility:
Viewable on computers, tablets, and smartphones with PDF reader.
⚙️ Engine Specifications
Primary Engine
Engine Type:
16-valve DOHC inline four-cylinder, Boxer-twin configuration (four cylinders opposed).
Displacement:
1171 cc (71.4 cu in)
Bore X Stroke:
77.6 mm x 64 mm (3.06 in x 2.52 in)
Compression Ratio:
10.8:1
Cooling System:
Liquid-cooled
Performance
Horsepower:
130 hp (97 kW) at 8,750 rpm
Torque:
113 Nm (83 lb-ft) at 6,750 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - Bosch Motronic MA 2.4
Fuel Type:
Unleaded premium gasoline (95 RON / 91 AKI minimum recommended)
Fuel Tank Capacity:
24 Liters (6.3 US gal)
Ignition
Ignition System:
Electronic ignition with knock sensor
🔧 Transmission
Standard
Transmission Type:
6-speed manual gearbox
Clutch:
Hydraulically operated multi-plate wet clutch
Final Drive:
Shaft drive
Features
Gear Ratios:
Ratio data available in manual (specific ratios vary per gear)
Transmission Fluid:
Refer to manual for specific fluid type and capacity (typically gear oil for final drive, manual transmission fluid for gearbox).
📐 Dimensions
Exterior
Length:
2,225 mm (87.6 in)
Width:
945 mm (37.2 in) (including mirrors)
Height:
1,430 mm (56.3 in) (at handlebars)
Wheelbase:
1,519 mm (59.8 in)
Weights
Dry Weight:
244 kg (538 lbs)
Wet Weight:
271 kg (597.5 lbs)
Maximum Load:
400 kg (882 lbs) (including rider, passenger, and luggage)
Wheels Tires
Front Tire Size:
120/70 ZR 17
Rear Tire Size:
170/60 ZR 17
Wheel Type:
Cast aluminum alloy
🛡️ Safety Features
Ratings
ABS System:
BMW Integral ABS (Generation 2)
Active Features
Braking System Design:
Linked braking (front and rear brakes partially actuated by either lever).
Chassis Stability:
Duolever front suspension for improved stability and feedback.
Passive Features
Lighting:
Halogen headlight, LED taillight, amber front and rear turn signals.
Ergonomics:
Adjustable handlebars and seat height (on some models/options) for rider comfort and control.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer and speedometer, LCD display for trip computer, gear indicator, fuel level, temperature, etc.
Audio System:
Optional integrated audio system on some models, controlled via handlebar switches.
Driver Assistance
ABS:
Integral ABS II, a sophisticated anti-lock braking system.
Suspension Control:
Electronic Suspension Adjustment (ESA) was an option on later models, not standard on all 2001-2005 models.
Connectivity
Diagnostic Port:
OBD-II compatible diagnostic connector for engine management system readings.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,200 miles) or annually, whichever comes first.
Valve Check Interval:
Every 20,000 km (12,400 miles) or as per manual recommendation.
Spark Plug Replacement:
Refer to manual, typically around 20,000-40,000 km.
Fluid Specifications
Engine Oil Type:
SAE 5W-40 Synthetic Motorcycle Oil (API SG/SH or higher, JASO MA approved). Refer to manual for exact BMW approval.
Engine Oil Capacity:
Approx. 4.0 Liters (4.2 US qt) with filter change.
Brake Fluid Type:
DOT 4 (refer to manual for specific BMW approval and replacement interval).
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors. BMW recommends BMW Advanced Antifreeze.
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, rear shock absorber (over time), ABS sensor rings.
Electrical Gremlins:
Relays, voltage regulator, and wiring harness integrity can be issues if not maintained; manual provides diagnostic paths.
Fuel System Maintenance:
Fuel pump and injector maintenance are critical for performance; manual details cleaning and testing.
📚 Vehicle History
Brand Heritage
Manufacturer:
Bayerische Motoren Werke AG (BMW)
Motorcycle Division Legacy:
BMW Motorrad has a long history of producing innovative and durable motorcycles since the 1920s.
Model Evolution
Predecessor:
BMW K1100LT and K1100RS.
Successor:
BMW K1200GT (introduced later).
Design Philosophy:
The K1200RS represented BMW's approach to a high-performance sport-touring machine, blending comfort, technology, and a distinctive engine configuration.
Production
Production Period For Model:
1996 - 2005 (This manual covers the later years of this generation).
Manufacturing Plant:
Berlin Spandau, Germany
🏆 Awards & Recognition
Recognitions
Review Acclaim:
Praised by motorcycle publications for its comfortable riding position, powerful engine, and touring capability.
Ratings
Owner Satisfaction:
Generally high owner satisfaction, particularly for long-distance comfort and build quality.
Certifications
Safety Certification:
Complies with relevant EU and US safety standards for motorcycles of its era.
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