BMW K1200 K1200RS 1997-2006 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: BMW Model: K1200RS Model Code: K589 Generation Generation Designation: First Generation K1200RS (shared platform with K1200GT) Codes Engine Code: K589 👋 Introduction Market Position Segment: Sport Touring Motorcycle Target Audience: BMW K1200RS owners seeking self-maintenance capabilities, independent repair shops, and enthusiasts focused on detailed technical knowledge. Competitive Analysis Competitors At Launch: Honda VFR800/VFRInterceptor, Kawasaki GTR1000, Yamaha FJR1300 (later models), Ducati ST series. Key Features Engine Configuration: Longitudinal inline-four cylinder engine Drivetrain: Shaft drive Suspension Design: BMW's Paralever single-sided swingarm with Monolever front suspension (early versions) and Telelever front suspension (later versions influenced by K1200LT). Electronics: Advanced for its time, including sophisticated fuel injection and optional ABS. 📋 Manual Details Coverage Areas Years Covered: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Page Count Estimated Page Count: Approximately 500-700 pages (typical for comprehensive workshop manuals) Manual Type Type: Workshop Repair and Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, valve train, lubrication, cooling system Engine Management: Fuel injection system (BMS), ignition system, emissions control, sensors, actuators Transmission Drivetrain: Clutch operation and adjustment, gearbox inspection and repair, final drive, driveshaft Chassis Suspension: Front suspension (forks), rear suspension (Paralever), wheel bearings, steering system Brakes: Brake system (front and rear), ABS system (if equipped), hydraulic lines, caliper service, rotor inspection Electrical System: Wiring diagrams, battery, alternator, starter motor, lighting system, instrumentation, fuses, relays Fuel System: Fuel tank, fuel pump, fuel lines, fuel filter replacement Bodywork Fairings: Fairing removal and installation, seat removal, tank cover access Diagnostic Troubleshooting: Diagnostic procedures, fault code interpretation, common problem diagnosis Procedures Included Routine Maintenance: Oil changes, filter replacements, chain/shaft maintenance, brake fluid changes, coolant flushes Major Overhauls: Engine rebuild, transmission overhaul, suspension component replacement Component Replacement: Brake pads, spark plugs, battery, tires, bulbs, cables Adjustment Procedures: Throttle cable, clutch cable, idle speed, suspension sag Troubleshooting Guides: Step-by-step diagnostics for various system failures Wiring Diagram Analysis: Interpreting electrical schematics for fault finding and repair Technical Depth Depth Of Information: Comprehensive: Covers everything from basic fluid checks to full engine and transmission rebuilds, including detailed torque specifications and diagnostic routines. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable PDF for quick information retrieval Print Quality Printability: Printable pages for workshop use Binding Type Binding: 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 (later increased) Bore X Stroke: 70.5 mm x 75 mm (initial) Compression Ratio: 10.0:1 (typical) Valvetrain: DOHC, 4 valves per cylinder Performance Horsepower: Approx. 107-110 hp @ 8000 rpm (early models), later models around 125-130 hp Torque: Approx. 95-100 Nm @ 6750 rpm (early models), later models around 115-120 Nm Fuel System Fuel Delivery: Electronic fuel injection (BMW Motor-Management System - BMS) Fuel Type: Unleaded premium gasoline (95 RON minimum recommended) Fuel Tank Capacity: 21 Liters (approx.) 🔧 Transmission Standard Type: 5-speed manual Optional Transmission Options: N/A (Standard 5-speed) Features Clutch: Hydraulically operated, multi-plate wet clutch Final Drive: Shaft drive 📐 Dimensions Exterior Length: Approx. 2240 mm Width: Approx. 910 mm (over handlebars) Height: Approx. 1370 mm (seat height adjustable) Weights Dry Weight: Approx. 245 kg Wet Weight: Approx. 260 kg (fully fueled and ready to ride) 🛡️ Safety Features Ratings ABS: Optional BMW Motorrad Integral ABS available on some models Active Features Braking System: Hydraulic dual disc front brakes, Hydraulic single disc rear brake Suspension Stability: Paralever rear and Telelever front suspension designed for stability during braking and cornering. Passive Features Fairing Protection: Full aerodynamic fairing providing wind and weather protection. Lighting: Halogen headlights for good visibility 💡 Technology Features Infotainment Instrumentation: Analog tachometer, speedometer, fuel gauge, coolant temperature gauge, gear indicator, and warning lights. Often includes a digital clock and trip meter. Driver Assistance ABS: Optional BMW Integral ABS (Anti-lock Braking System) provided enhanced safety and stability. Connectivity Diagnostics Port: On-board diagnostics connector for fault code reading and system analysis. 🔧 Maintenance Service Intervals Oil Change Interval: Every 10,000 km or annually, whichever comes first (refer to manual for specific grade and capacity). Valve Clearance Check: Every 20,000 km (critical for engine health). Brake Fluid Change: Every 2 years Coolant Flush: Every 3-4 years or as per manual recommendation. Fluid Specifications Engine Oil Type: Synthetic motorcycle oil, e.g., SAE 10W-40 or 15W-50 (refer to manual for precise BMW specifications and capacities). Transmission Oil: Gear oil, typically SAE 75W-90 or 80W-90 (refer to manual for exact BMW specification and capacity). Brake Fluid Type: DOT 4 brake fluid (refer to manual for specific BMW recommendations). Coolant Type: Ethylene glycol-based coolant with corrosion inhibitors (BMW approved mix, typically 50/50 with distilled water). Known Issues Common Wear Items: Clutch wear, suspension seals (forks, shock), wheel bearings, fuel pump issues (early models), starter motor solenoid....
BMW's Paralever single-sided swingarm with Monolever front suspension (early versions) and Telelever front suspension (later versions influenced by K1200LT).
Electronics:
Advanced for its time, including sophisticated fuel injection and optional ABS.
Throttle cable, clutch cable, idle speed, suspension sag
Troubleshooting Guides:
Step-by-step diagnostics for various system failures
Wiring Diagram Analysis:
Interpreting electrical schematics for fault finding and repair
Technical Depth
Depth Of Information:
Comprehensive: Covers everything from basic fluid checks to full engine and transmission rebuilds, including detailed torque specifications and diagnostic routines.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable PDF for quick information retrieval
Print Quality
Printability:
Printable pages for workshop use
Binding Type
Binding:
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 (later increased)
Bore X Stroke:
70.5 mm x 75 mm (initial)
Compression Ratio:
10.0:1 (typical)
Valvetrain:
DOHC, 4 valves per cylinder
Performance
Horsepower:
Approx. 107-110 hp @ 8000 rpm (early models), later models around 125-130 hp
Torque:
Approx. 95-100 Nm @ 6750 rpm (early models), later models around 115-120 Nm
Fuel System
Fuel Delivery:
Electronic fuel injection (BMW Motor-Management System - BMS)
Fuel Type:
Unleaded premium gasoline (95 RON minimum recommended)
Fuel Tank Capacity:
21 Liters (approx.)
🔧 Transmission
Standard
Type:
5-speed manual
Optional
Transmission Options:
N/A (Standard 5-speed)
Features
Clutch:
Hydraulically operated, multi-plate wet clutch
Final Drive:
Shaft drive
📐 Dimensions
Exterior
Length:
Approx. 2240 mm
Width:
Approx. 910 mm (over handlebars)
Height:
Approx. 1370 mm (seat height adjustable)
Weights
Dry Weight:
Approx. 245 kg
Wet Weight:
Approx. 260 kg (fully fueled and ready to ride)
🛡️ Safety Features
Ratings
ABS:
Optional BMW Motorrad Integral ABS available on some models
Active Features
Braking System:
Hydraulic dual disc front brakes, Hydraulic single disc rear brake
Suspension Stability:
Paralever rear and Telelever front suspension designed for stability during braking and cornering.
Passive Features
Fairing Protection:
Full aerodynamic fairing providing wind and weather protection.
Lighting:
Halogen headlights for good visibility
💡 Technology Features
Infotainment
Instrumentation:
Analog tachometer, speedometer, fuel gauge, coolant temperature gauge, gear indicator, and warning lights. Often includes a digital clock and trip meter.
Driver Assistance
ABS:
Optional BMW Integral ABS (Anti-lock Braking System) provided enhanced safety and stability.
Connectivity
Diagnostics Port:
On-board diagnostics connector for fault code reading and system analysis.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km or annually, whichever comes first (refer to manual for specific grade and capacity).
Valve Clearance Check:
Every 20,000 km (critical for engine health).
Brake Fluid Change:
Every 2 years
Coolant Flush:
Every 3-4 years or as per manual recommendation.
Fluid Specifications
Engine Oil Type:
Synthetic motorcycle oil, e.g., SAE 10W-40 or 15W-50 (refer to manual for precise BMW specifications and capacities).
Transmission Oil:
Gear oil, typically SAE 75W-90 or 80W-90 (refer to manual for exact BMW specification and capacity).
Brake Fluid Type:
DOT 4 brake fluid (refer to manual for specific BMW recommendations).
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (BMW approved mix, typically 50/50 with distilled water).
Can be prone to electrical issues due to complex wiring, particularly related to the ABS and BMS systems. Loose connections or corrosion can cause intermittent problems.
Thermostat Housing:
Potential for leaks from the thermostat housing or associated hoses.
ABS Module Failures:
ABS control modules can be expensive to replace if they fail. Proper maintenance of the ABS sensors and fluid is crucial.
📚 Vehicle History
Brand Heritage
Brand Focus:
BMW Motorrad, known for engineering excellence, durability, and rider comfort, particularly in the touring and sport-touring segments.
Model Evolution
Predecessor:
BMW K1100RS
Successor:
BMW K1200S, K1200GT (New Generation)
Production
Manufacturing Location:
Berlin, Germany
Production Period:
1997 - 2006
🏆 Awards & Recognition
Recognitions
Industry Recognition:
Widely praised for its comfort, wind protection, and long-distance capability. Competed effectively in the premium sport-touring market.
Ratings
Rider Magazine Reviews:
Consistently rated highly for its performance, handling, and build quality by major motorcycle publications of its era.
Certifications
Emissions Standards:
Compliant with European emissions standards applicable during its production years.