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BMW K1200 1997-2004 Workshop Service Manual Repair

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🏷️ Basic Information Identification Make: BMW Model: K1200 Model Years Covered: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Codes Chassis Code Range: K589 (K1200RS), K589/1 (K1200LT) 👋 Introduction Market Position Market Segment: Luxury Sport Touring Motorcycle Target Audience: Riders seeking comfortable, powerful, and technologically advanced motorcycles for long-distance touring and sporty riding. Competitive Analysis Key Competitors: Honda Gold Wing, Yamaha FJR1300, Kawasaki Concours 14 (later models). Key Features Distinctive Features: Revolutionary Duolever front suspension (K1200RS), integrated ABS, powerful inline-four engine, comfortable riding position, extensive touring amenities on LT model. Manual Value Proposition: Essential resource for owners and independent mechanics to maintain, diagnose, and repair these complex German motorcycles, saving time and money on dealership service. 📋 Manual Details Coverage Areas Primary Models Covered: BMW K1200RS, BMW K1200LT Page Count Estimated Page Count: 500+ Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanics: Complete engine overhaul, disassembly, assembly, valve adjustments, timing chain, lubrication system, cooling system. Fuel System: Fuel injection system (Bosch Motronic), fuel pump, injectors, throttle body, fuel lines, fuel tank. Transmission And Drivetrain: Gearbox disassembly and assembly, clutch operation and adjustment, driveshaft, final drive. Suspension And Steering: Front fork (Duolever system for RS, Telelever for LT), rear shock absorber, linkage, steering head bearing, wheel bearings. Brakes: Integral ABS II braking system, brake calipers, master cylinders, brake lines, bleeding procedures, rotor inspection. Electrical System: Wiring diagrams, battery, alternator, starter motor, ignition system, lighting, instrument cluster, ECU diagnostics. Bodywork And Chassis: Fairing removal and installation, seat, fuel tank mounting, chassis components, subframe. Heating And Air Conditioning: Detailed procedures for K1200LT HVAC system. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant flush, chain lubrication (if applicable, though shaft drive is primary). Troubleshooting: Diagnostic charts, common problems and their solutions, error code interpretation. Repair And Overhaul: Step-by-step instructions for major component repairs and full rebuilds. Electrical Diagnostics: Wiring diagram interpretation, testing electrical components, troubleshooting sensor issues. Component Replacement: Detailed guidance on replacing parts like brake pads, clutch plates, bearings, etc. Technical Depth Technical Depth: Comprehensive, covering from basic maintenance to full engine and drivetrain rebuilds, including complex electrical systems and ABS diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for easy navigation. Print Quality Print Quality: Digital, quality depends on original source and user printing capabilities. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, inline four-cylinder Displacement: 1171 cc (for most K1200 variants of this era) Bore X Stroke: 70.5 mm x 75 mm Compression Ratio: 10.0:1 Performance Horsepower: Approx. 130 hp @ 8,500 rpm Torque: Approx. 110 Nm (81 lb-ft) @ 6,750 rpm Fuel System Fuel Delivery: Electronic fuel injection (Bosch Motronic) Fuel Type: Unleaded gasoline, octane rating 91 or higher 🔧 Transmission Standard Transmission Type: 5-speed manual gearbox Optional Optional Transmission: N/A (Standard manual) Features Clutch Type: Hydraulically operated, multi-plate wet clutch Final Drive: Shaft drive 📐 Dimensions Exterior Length K1200Rs: Approx. 2,170 mm (85.4 in) Width K1200Rs: Approx. 720 mm (28.3 in) (excluding mirrors) Height K1200Rs: Approx. 1,250 mm (49.2 in) (adjustable windscreen) Weights Dry Weight K1200Rs: Approx. 224 kg (494 lbs) Gross Vehicle Weight Rating K1200Rs: Approx. 450 kg (992 lbs) Wet Weight K1200Lt: Approx. 330 kg (728 lbs) 🛡️ Safety Features Ratings ABS System: BMW Integral ABS II (standard on most models/years) Active Features Braking Performance: Excellent stopping power and stability, especially with ABS engaged. Passive Features Frame Construction: Robust chassis designed for stability and handling. 💡 Technology Features Infotainment K1200Lt Features: Integrated audio system (often with cassette/CD), cruise control, electric windscreen, heated grips and seats (optional/standard depending on spec). Driver Assistance ABS: Integral ABS II provides synchronized braking control and stability. Cruise Control: Standard on K1200LT, optional on some K1200RS models, offering long-distance comfort. Connectivity Diagnostic Interface: BMW proprietary diagnostic port allowing connection to diagnostic tools for fault code reading and system analysis. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000 km (6,000 miles) or annually, whichever comes first. Valve Check Interval: Around 20,000 km - 40,000 km (12,000 - 24,000 miles), depending on specific model year and usage. Brake Fluid Flush: Every 2 years Fluid Specifications Engine Oil Type: SAE 15W-50 API SG or higher (check specific manual for exact spec) Engine Oil Capacity: Approx. 4.0 - 4.5 liters (check manual) Coolant Type: BMW approved coolant (ethylene glycol based with corrosion inhibitors) Transmission Oil Type: SAE 75W-90 API GL-4 or GL-5 (check manual) Final Drive Oil Type: SAE 80W-90 API GL-5 (check manual) Known Issues Common Wear Items: Wheel bearings, steering head bearings, clutch slave cylinder, starter motor brushes. Electrical Gremlins: Intermittent issues related to wiring harness connections, particularly on the...
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BMW K1200 1997-2004 Workshop Service Manual Repair
🏷️ Basic Information
Identification
Make:
BMW
Model:
K1200
Model Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Codes
Chassis Code Range:
K589 (K1200RS), K589/1 (K1200LT)
👋 Introduction
Market Position
Market Segment:
Luxury Sport Touring Motorcycle
Target Audience:
Riders seeking comfortable, powerful, and technologically advanced motorcycles for long-distance touring and sporty riding.
Competitive Analysis
Key Competitors:
Honda Gold Wing, Yamaha FJR1300, Kawasaki Concours 14 (later models).
Key Features
Distinctive Features:
Revolutionary Duolever front suspension (K1200RS), integrated ABS, powerful inline-four engine, comfortable riding position, extensive touring amenities on LT model.
Manual Value Proposition:
Essential resource for owners and independent mechanics to maintain, diagnose, and repair these complex German motorcycles, saving time and money on dealership service.
📋 Manual Details
Coverage Areas
Primary Models Covered:
BMW K1200RS, BMW K1200LT
Page Count
Estimated Page Count:
500+
Manual Type
Manual Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanics:
Complete engine overhaul, disassembly, assembly, valve adjustments, timing chain, lubrication system, cooling system.
Fuel System:
Fuel injection system (Bosch Motronic), fuel pump, injectors, throttle body, fuel lines, fuel tank.
Transmission And Drivetrain:
Gearbox disassembly and assembly, clutch operation and adjustment, driveshaft, final drive.
Suspension And Steering:
Front fork (Duolever system for RS, Telelever for LT), rear shock absorber, linkage, steering head bearing, wheel bearings.
Brakes:
Integral ABS II braking system, brake calipers, master cylinders, brake lines, bleeding procedures, rotor inspection.
Electrical System:
Wiring diagrams, battery, alternator, starter motor, ignition system, lighting, instrument cluster, ECU diagnostics.
Bodywork And Chassis:
Fairing removal and installation, seat, fuel tank mounting, chassis components, subframe.
Heating And Air Conditioning:
Detailed procedures for K1200LT HVAC system.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant flush, chain lubrication (if applicable, though shaft drive is primary).
Troubleshooting:
Diagnostic charts, common problems and their solutions, error code interpretation.
Repair And Overhaul:
Step-by-step instructions for major component repairs and full rebuilds.
Electrical Diagnostics:
Wiring diagram interpretation, testing electrical components, troubleshooting sensor issues.
Component Replacement:
Detailed guidance on replacing parts like brake pads, clutch plates, bearings, etc.
Technical Depth
Technical Depth:
Comprehensive, covering from basic maintenance to full engine and drivetrain rebuilds, including complex electrical systems and ABS diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF for easy navigation.
Print Quality
Print Quality:
Digital, quality depends on original source and user printing capabilities.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, inline four-cylinder
Displacement:
1171 cc (for most K1200 variants of this era)
Bore X Stroke:
70.5 mm x 75 mm
Compression Ratio:
10.0:1
Performance
Horsepower:
Approx. 130 hp @ 8,500 rpm
Torque:
Approx. 110 Nm (81 lb-ft) @ 6,750 rpm
Fuel System
Fuel Delivery:
Electronic fuel injection (Bosch Motronic)
Fuel Type:
Unleaded gasoline, octane rating 91 or higher
🔧 Transmission
Standard
Transmission Type:
5-speed manual gearbox
Optional
Optional Transmission:
N/A (Standard manual)
Features
Clutch Type:
Hydraulically operated, multi-plate wet clutch
Final Drive:
Shaft drive
📐 Dimensions
Exterior
Length K1200Rs:
Approx. 2,170 mm (85.4 in)
Width K1200Rs:
Approx. 720 mm (28.3 in) (excluding mirrors)
Height K1200Rs:
Approx. 1,250 mm (49.2 in) (adjustable windscreen)
Weights
Dry Weight K1200Rs:
Approx. 224 kg (494 lbs)
Gross Vehicle Weight Rating K1200Rs:
Approx. 450 kg (992 lbs)
Wet Weight K1200Lt:
Approx. 330 kg (728 lbs)
🛡️ Safety Features
Ratings
ABS System:
BMW Integral ABS II (standard on most models/years)
Active Features
Braking Performance:
Excellent stopping power and stability, especially with ABS engaged.
Passive Features
Frame Construction:
Robust chassis designed for stability and handling.
💡 Technology Features
Infotainment
K1200Lt Features:
Integrated audio system (often with cassette/CD), cruise control, electric windscreen, heated grips and seats (optional/standard depending on spec).
Driver Assistance
ABS:
Integral ABS II provides synchronized braking control and stability.
Cruise Control:
Standard on K1200LT, optional on some K1200RS models, offering long-distance comfort.
Connectivity
Diagnostic Interface:
BMW proprietary diagnostic port allowing connection to diagnostic tools for fault code reading and system analysis.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 km (6,000 miles) or annually, whichever comes first.
Valve Check Interval:
Around 20,000 km - 40,000 km (12,000 - 24,000 miles), depending on specific model year and usage.
Brake Fluid Flush:
Every 2 years
Fluid Specifications
Engine Oil Type:
SAE 15W-50 API SG or higher (check specific manual for exact spec)
Engine Oil Capacity:
Approx. 4.0 - 4.5 liters (check manual)
Coolant Type:
BMW approved coolant (ethylene glycol based with corrosion inhibitors)
Transmission Oil Type:
SAE 75W-90 API GL-4 or GL-5 (check manual)
Final Drive Oil Type:
SAE 80W-90 API GL-5 (check manual)
Known Issues
Common Wear Items:
Wheel bearings, steering head bearings, clutch slave cylinder, starter motor brushes.
Electrical Gremlins:
Intermittent issues related to wiring harness connections, particularly on the LT model due to complex systems.
Fuel Pump Reliability:
Early fuel pumps could be a point of failure, though often fixable with proper diagnostic procedures.
ABS System Maintenance:
Regular fluid changes and bleeding are crucial for ABS performance; sensor cleaning might be required.
📚 Vehicle History
Brand Heritage
Bmw Motorrad Legacy:
BMW Motorrad has a long history of producing innovative and high-quality motorcycles, known for their engineering prowess and durability, particularly in touring and sport-touring segments.
Model Evolution
K Series Development:
The K1200 models represent a significant evolution of BMW's K-series, featuring the innovative transverse inline-four engine and advanced suspension systems, moving towards more sporty and technologically advanced platforms compared to earlier K-series bikes.
Production
Manufacturing Origin:
Germany
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
While specific awards might not be readily available for this model year, BMW motorcycles consistently receive high marks from critics for engineering, performance, and build quality in the sport-touring segment.
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