BMW K1200GT R S Motorcycle Complete Workshop Service Repair Manual 2002 2003 2004 2005
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🏷️ Basic Information Identification Make: BMW Model: K1200GT R S Product Type: Complete Workshop Service Repair Manual 👋 Introduction Market Position Positioning: High-performance touring motorcycle, aimed at riders seeking comfort, power, and advanced technology for long-distance travel. Competitive Analysis Competitors: Likely competitors included models from Honda (e.g., ST1300), Yamaha (e.g., FJR1300), Kawasaki (e.g., Concours 14), and potentially some Harley-Davidson touring models. Key Features Features: Inline four-cylinder engine, shaft drive, adjustable suspension, integrated luggage, ergonomic rider triangle, advanced electronics (for its time). Manual Benefit Cost Saving: Enables owners to perform repairs and maintenance, significantly reducing labor costs at dealerships. Ease Of Use: Step-by-step instructions and pictures facilitate straightforward service and repair tasks. 📋 Manual Details Coverage Areas Years Covered: 2002, 2003, 2004, 2005 Models Covered: All K1200GT R S models, engines, trim, and transmission types Specific Variants: Includes K1200RS and K1200GT variants, recognizing their shared platform and evolution. Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable (PDF) Accessibility: Printable, tablet/smartphone compatible Software Requirements Required Software: Adobe Reader (free download) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, tuning, diagnostics, fuel system, ignition system, lubrication system Transmission: Gearbox inspection, repair, clutch service, final drive, drive shaft Chassis: Frame inspection, suspension (front and rear), steering, wheels, tires Brakes: Brake system maintenance, repair, ABS system details, hydraulic components Electrical: Wiring diagrams, battery, charging system, lighting, ignition system, ECU diagnostics, instrument cluster Bodywork And Trim: Fairing removal and installation, seat, luggage systems, body panel repairs Fuel System Details: Fuel pump testing, injector cleaning and testing, throttle body synchronization, pressure regulator checks. Ignition System Details: Spark plug specifications and replacement, ignition coil testing, crankshaft position sensor checks, camshaft position sensor diagnostics. Suspension System: Front fork seal replacement, rear shock absorber service and adjustment, linkage inspection. Cooling System: Coolant flush and fill, radiator inspection, thermostat testing, fan operation checks. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, coolant service, brake fluid changes, spark plug replacement Troubleshooting: Step-by-step diagnostic procedures for common and complex issues Repair: Detailed instructions for component removal, repair, and reinstallation Technical Data: Specifications, torque values, clearances, fluid capacities, electrical resistance values Wheel And Tire Service: Tire replacement, wheel balancing, spoke tensioning (if applicable), bearing checks. Fastener Torquing: Comprehensive list of torque specifications for all critical fasteners, engine components, chassis parts, and bodywork. Technical Depth Depth: Comprehensive (A-Z coverage of all repair and service procedures) Wiring Diagrams: Detailed, high-resolution wiring diagrams covering all electrical systems, allowing for complex troubleshooting. Diagnostic Troubleshooting: Specific fault code meanings and diagnostic trees for identifying and resolving electronic issues. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High quality, clear text and images Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, DOHC, inline four-cylinder Displacement: 1171 cc (for K1200GT/RS models of this era) Bore X Stroke: 79 mm x 59 mm Performance Horsepower Approx: 130-140 hp (at crankshaft, depending on exact model variant and tuning) Torque Approx: 115-120 Nm (at crankshaft, depending on exact model variant and tuning) Fuel System Fuel Delivery: Electronic fuel injection (EFI), often BMW's Motronic system Fuel Type: Unleaded gasoline, minimum 95 RON (Research Octane Number) Lubrication System Oil Type Spec: Refer to manual for specific BMW approval, typically SAE 5W-40 or 10W-40 synthetic motorcycle oil Ignition System Ignition: Electronic ignition, typically with dual spark plugs per cylinder for improved combustion efficiency. 🔧 Transmission Standard Type: 6-speed manual gearbox Drive Type Final Drive: Shaft drive Clutch Clutch Type: Hydraulically operated, multi-plate wet clutch Fluid Specifications Gearbox Oil: Refer to manual for specific BMW approval, typically SAE 75W-90 or 80W-90 hypoid gear oil 📐 Dimensions Exterior Length Approx: 2,220 mm (87.4 in) Width Approx: 930 mm (36.6 in) Height Approx: 1,430 mm (56.3 in) Weights Dry Weight Approx: 243 kg (535.7 lbs) Wet Weight Approx: 270 kg (595.2 lbs) Fuel Capacity Fuel Tank Capacity: 24 Liters (6.3 US gal), including 4 Liters (1.1 US gal) reserve 🛡️ Safety Features Ratings Braking System: BMW Motorrad Integral ABS (Anti-lock Braking System), often with linked braking functionality. Active Features ABS: Standard fitment on most models, enhancing braking stability. Passive Features Lighting: Halogen headlights, integrated turn signals, LED taillight. 💡 Technology Features Infotainment Instrument Cluster: Digital/analog combination with comprehensive readouts, including gear indicator, fuel level, engine temperature, and fault codes. Driver Assistance Cruise Control: Often available as an option or standard on GT models, providing enhanced long-distance comfort. Connectivity Diagnostic Port: Standard BMW diagnostic connector for electronic 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. Major Service Interval: Major inspections and component checks usually recommended every 20,000 km (12,000 miles) or biennially. Fluid Specifications Coolant Type: BMW approved coolant, typically a 50/50...
130-140 hp (at crankshaft, depending on exact model variant and tuning)
Torque Approx:
115-120 Nm (at crankshaft, depending on exact model variant and tuning)
Fuel System
Fuel Delivery:
Electronic fuel injection (EFI), often BMW's Motronic system
Fuel Type:
Unleaded gasoline, minimum 95 RON (Research Octane Number)
Lubrication System
Oil Type Spec:
Refer to manual for specific BMW approval, typically SAE 5W-40 or 10W-40 synthetic motorcycle oil
Ignition System
Ignition:
Electronic ignition, typically with dual spark plugs per cylinder for improved combustion efficiency.
🔧 Transmission
Standard
Type:
6-speed manual gearbox
Drive Type
Final Drive:
Shaft drive
Clutch
Clutch Type:
Hydraulically operated, multi-plate wet clutch
Fluid Specifications
Gearbox Oil:
Refer to manual for specific BMW approval, typically SAE 75W-90 or 80W-90 hypoid gear oil
📐 Dimensions
Exterior
Length Approx:
2,220 mm (87.4 in)
Width Approx:
930 mm (36.6 in)
Height Approx:
1,430 mm (56.3 in)
Weights
Dry Weight Approx:
243 kg (535.7 lbs)
Wet Weight Approx:
270 kg (595.2 lbs)
Fuel Capacity
Fuel Tank Capacity:
24 Liters (6.3 US gal), including 4 Liters (1.1 US gal) reserve
🛡️ Safety Features
Ratings
Braking System:
BMW Motorrad Integral ABS (Anti-lock Braking System), often with linked braking functionality.
Active Features
ABS:
Standard fitment on most models, enhancing braking stability.
Passive Features
Lighting:
Halogen headlights, integrated turn signals, LED taillight.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital/analog combination with comprehensive readouts, including gear indicator, fuel level, engine temperature, and fault codes.
Driver Assistance
Cruise Control:
Often available as an option or standard on GT models, providing enhanced long-distance comfort.
Connectivity
Diagnostic Port:
Standard BMW diagnostic connector for electronic 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.
Major Service Interval:
Major inspections and component checks usually recommended every 20,000 km (12,000 miles) or biennially.
Fluid Specifications
Coolant Type:
BMW approved coolant, typically a 50/50 mix of ethylene glycol and distilled water.
Brake Fluid:
DOT 4 synthetic brake fluid.
Known Issues
Common Wear Items:
Clutch wear, final drive spline lubrication, fuel pump reliability, rear shock absorber performance (especially on higher mileage units).
Electrical Concerns:
Occasional issues with wiring harness integrity, especially in high-vibration areas, and alternator/rectifier performance.
Fuel System Maintenance:
Regular fuel filter replacement and injector cleaning can prevent performance issues.
📚 Vehicle History
Brand Heritage
Heritage:
BMW Motorrad, renowned for its engineering excellence, reliable motorcycles, and pioneering technology, particularly in touring and adventure segments.
Model Evolution
K Series Evolution:
The K1200GT/RS models are part of BMW's K-series, which debuted with the revolutionary K100 'flying brick' engine in the 1980s. Subsequent generations evolved the inline-four configuration, improving performance, ergonomics, and technology.
Production
Production Period:
The K1200GT/RS platform was produced from the late 1990s through the mid-2000s, with this manual covering specific years of refinement.
🏆 Awards & Recognition
Recognitions
Awards And Ratings:
While specific awards for this model year might be scarce in readily available public records, the K1200GT series was generally well-regarded by motorcycle press for its performance, comfort, and technology, contributing to BMW's reputation in the sport-touring segment.