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BMW K1200 1997-2004 Workshop Service Manual Repair

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๐Ÿท๏ธ 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) ๐Ÿ‘‹ 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. ๐Ÿ“‹ 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 ๐Ÿ“– 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. ๐Ÿ“Š 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) โš™๏ธ 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 ๐Ÿ”ง 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 ๐Ÿ“ 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) ๐Ÿ›ก๏ธ 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. ๐Ÿ’ก 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. ๐Ÿ”ง 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
๐Ÿท๏ธ 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)
๐Ÿ‘‹ 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.
๐Ÿ“‹ 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
๐Ÿ“– 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.
๐Ÿ“Š 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)
โš™๏ธ 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
๐Ÿ”ง 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
๐Ÿ“ 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)
๐Ÿ›ก๏ธ 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.
๐Ÿ’ก 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.
๐Ÿ”ง 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.
๐Ÿ“š 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
๐Ÿ† 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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