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BMW K1200S K40 2004-2008 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: R1200S Model Code: K40 Generation Generation Designation: First Generation R1200S Codes Chassis Code: K40 👋 Introduction Market Position Segment: Sport Touring Motorcycle Target Audience: Enthusiast owners of BMW R1200S (K40) seeking to perform their own maintenance and repairs, and professional motorcycle technicians. Competitive Analysis Key Competitors: Other large-displacement sport-touring bikes of the era, such as Yamaha FJR1300, Kawasaki GTR1400, Honda VFR1200F (though the VFR1200F is later), and some Ducati models. Key Features Vehicle Strengths: Powerful Boxer engine, shaft drive, sophisticated chassis and suspension, comfortable for long distances, BMW's reputation for build quality and technology. Manual Value Proposition: Essential for cost-effective maintenance, accurate part ordering, and efficient troubleshooting, empowering owners to maintain their premium motorcycle. 📋 Manual Details Coverage Areas Coverage Span: 2004-2008 Model Years Page Count Estimated Page Count: Comprehensive (Exact count not specified, but typical for full service manuals) Manual Type Type: Service and Repair Manual Language Language: English (Assumed based on product description) Format Format: Digital Download (PDF implied by 'INSTANT DOWNLOAD') 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical (cylinder head, piston, crankshaft, camshaft), fuel system (injection, throttle bodies, fuel pump), ignition system, lubrication system, cooling system (liquid cooling components), exhaust system. Drivetrain Systems: Transmission (gearbox operation, shifting mechanism), clutch operation and service, final drive (shaft drive, universal joint, bevel gear). Chassis Systems: Frame, front suspension (fork disassembly, adjustment), rear suspension (Paralever system, shock absorber service), steering system, braking system (hydraulic lines, caliper service, ABS components), wheel and tire service. Electrical Systems: Wiring diagrams, battery maintenance, alternator, starter motor, lighting system (headlights, taillights, turn signals), instrument cluster, ECU (Engine Control Unit) and sensor diagnostics, ABS control unit. Bodywork And Accessories: Fairing removal and installation, seat service, fuel tank service, side stand, center stand, luggage mounting points. Procedures Included Maintenance Procedures: Scheduled maintenance, oil and filter changes, coolant checks and changes, brake fluid flushes, spark plug replacement, air filter service, drive shaft lubrication, valve clearance checks and adjustments. Repair Procedures: Complete engine overhaul, transmission rebuild, clutch replacement, fork seal replacement, shock absorber overhaul, brake caliper rebuild, ABS bleeding procedures, electrical component troubleshooting and replacement. Diagnostic Procedures: Troubleshooting guides for common malfunctions, fault code reading (if applicable to the era and diagnostic tools), performance diagnosis. Assembly Disassembly: Detailed step-by-step instructions for component removal and installation, torque specifications for all fasteners. Technical Depth Depth: Comprehensive: Covers basic to advanced repair and overhaul procedures, suitable for both home mechanics and professional technicians. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable if professionally scanned, allowing quick access to specific topics. Print Quality Quality: High-resolution scans of original factory documentation, ensuring clarity of text and diagrams. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Air/Oil-cooled, Four-stroke, Boxer-twin engine Displacement: 1170 cc (71.4 cu in) Bore X Stroke: 101 mm x 73 mm (approximate) Compression Ratio: 12.5:1 Valve Train: DOHC, 4 valves per cylinder, chain driven Performance Horsepower: 125 hp (93 kW) @ 7500 rpm (approximate for R1200S variant) Torque: 85 lb-ft (115 Nm) @ 6000 rpm (approximate for R1200S variant) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with individual throttle bodies Fuel Type: Unleaded premium gasoline, minimum 95 RON (91 AKI) Fuel Tank Capacity: 21 liters (5.5 US gal) Lubrication System Oil Type: Synthetic SAE 15W-50 Motorcycle Oil (refer to manual for exact BMW approval) Oil Capacity With Filter Change: Approx. 4.0 liters (refer to manual for exact capacity) 🔧 Transmission Standard Transmission Type: 6-speed manual gearbox Optional Optional Transmission: N/A (No automatic option for this model) Features Drive System: Shaft drive via BMW's Paralever single-sided swingarm Clutch Type: Hydraulically operated dry clutch Final Drive Oil Type: BMW recommended hypoid gear oil SAE 90 or equivalent (refer to manual for specific BMW approval) 📐 Dimensions Exterior Length: 2230 mm (87.8 in) Width Over Handlebars: 950 mm (37.4 in) Height Over Seat: 1300 mm (51.2 in) (approximate, unladen) Seat Height: 800 mm (31.5 in) (standard seat) Weights Dry Weight: 217 kg (478 lbs) Gross Vehicle Weight Rating: 450 kg (992 lbs) Payload Capacity: 233 kg (514 lbs) Wheelbase: 1500 mm (59.1 in) 🛡️ Safety Features Ratings ABS: Integral ABS (available, integrated braking system) Active Features Braking System Front: Dual 320 mm discs, 4-piston fixed caliper Braking System Rear: Single 265 mm disc, 2-piston floating caliper Suspension Front: BMW Telelever (or conventional upside-down forks depending on exact year/variant, R1200S used conventional) Suspension Rear: BMW Paralever (single-sided swingarm with adjustable shock absorber) Passive Features Lighting: Halogen headlight, LED taillight, amber turn signals 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer and speedometer, LCD display for gear indicator, fuel level, trip computer, engine temperature, time, and warning lights. Options for heated grips, ABS indicators. Driver Assistance ABS System: BMW Integral...
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BMW K1200S K40 2004-2008 Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
R1200S
Model Code:
K40
Generation
Generation Designation:
First Generation R1200S
Codes
Chassis Code:
K40
👋 Introduction
Market Position
Segment:
Sport Touring Motorcycle
Target Audience:
Enthusiast owners of BMW R1200S (K40) seeking to perform their own maintenance and repairs, and professional motorcycle technicians.
Competitive Analysis
Key Competitors:
Other large-displacement sport-touring bikes of the era, such as Yamaha FJR1300, Kawasaki GTR1400, Honda VFR1200F (though the VFR1200F is later), and some Ducati models.
Key Features
Vehicle Strengths:
Powerful Boxer engine, shaft drive, sophisticated chassis and suspension, comfortable for long distances, BMW's reputation for build quality and technology.
Manual Value Proposition:
Essential for cost-effective maintenance, accurate part ordering, and efficient troubleshooting, empowering owners to maintain their premium motorcycle.
📋 Manual Details
Coverage Areas
Coverage Span:
2004-2008 Model Years
Page Count
Estimated Page Count:
Comprehensive (Exact count not specified, but typical for full service manuals)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English (Assumed based on product description)
Format
Format:
Digital Download (PDF implied by 'INSTANT DOWNLOAD')
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical (cylinder head, piston, crankshaft, camshaft), fuel system (injection, throttle bodies, fuel pump), ignition system, lubrication system, cooling system (liquid cooling components), exhaust system.
Drivetrain Systems:
Transmission (gearbox operation, shifting mechanism), clutch operation and service, final drive (shaft drive, universal joint, bevel gear).
Chassis Systems:
Frame, front suspension (fork disassembly, adjustment), rear suspension (Paralever system, shock absorber service), steering system, braking system (hydraulic lines, caliper service, ABS components), wheel and tire service.
Electrical Systems:
Wiring diagrams, battery maintenance, alternator, starter motor, lighting system (headlights, taillights, turn signals), instrument cluster, ECU (Engine Control Unit) and sensor diagnostics, ABS control unit.
Bodywork And Accessories:
Fairing removal and installation, seat service, fuel tank service, side stand, center stand, luggage mounting points.
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil and filter changes, coolant checks and changes, brake fluid flushes, spark plug replacement, air filter service, drive shaft lubrication, valve clearance checks and adjustments.
Repair Procedures:
Complete engine overhaul, transmission rebuild, clutch replacement, fork seal replacement, shock absorber overhaul, brake caliper rebuild, ABS bleeding procedures, electrical component troubleshooting and replacement.
Diagnostic Procedures:
Troubleshooting guides for common malfunctions, fault code reading (if applicable to the era and diagnostic tools), performance diagnosis.
Assembly Disassembly:
Detailed step-by-step instructions for component removal and installation, torque specifications for all fasteners.
Technical Depth
Depth:
Comprehensive: Covers basic to advanced repair and overhaul procedures, suitable for both home mechanics and professional technicians.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable if professionally scanned, allowing quick access to specific topics.
Print Quality
Quality:
High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air/Oil-cooled, Four-stroke, Boxer-twin engine
Displacement:
1170 cc (71.4 cu in)
Bore X Stroke:
101 mm x 73 mm (approximate)
Compression Ratio:
12.5:1
Valve Train:
DOHC, 4 valves per cylinder, chain driven
Performance
Horsepower:
125 hp (93 kW) @ 7500 rpm (approximate for R1200S variant)
Torque:
85 lb-ft (115 Nm) @ 6000 rpm (approximate for R1200S variant)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with individual throttle bodies
Fuel Type:
Unleaded premium gasoline, minimum 95 RON (91 AKI)
Fuel Tank Capacity:
21 liters (5.5 US gal)
Lubrication System
Oil Type:
Synthetic SAE 15W-50 Motorcycle Oil (refer to manual for exact BMW approval)
Oil Capacity With Filter Change:
Approx. 4.0 liters (refer to manual for exact capacity)
🔧 Transmission
Standard
Transmission Type:
6-speed manual gearbox
Optional
Optional Transmission:
N/A (No automatic option for this model)
Features
Drive System:
Shaft drive via BMW's Paralever single-sided swingarm
Clutch Type:
Hydraulically operated dry clutch
Final Drive Oil Type:
BMW recommended hypoid gear oil SAE 90 or equivalent (refer to manual for specific BMW approval)
📐 Dimensions
Exterior
Length:
2230 mm (87.8 in)
Width Over Handlebars:
950 mm (37.4 in)
Height Over Seat:
1300 mm (51.2 in) (approximate, unladen)
Seat Height:
800 mm (31.5 in) (standard seat)
Weights
Dry Weight:
217 kg (478 lbs)
Gross Vehicle Weight Rating:
450 kg (992 lbs)
Payload Capacity:
233 kg (514 lbs)
Wheelbase:
1500 mm (59.1 in)
🛡️ Safety Features
Ratings
ABS:
Integral ABS (available, integrated braking system)
Active Features
Braking System Front:
Dual 320 mm discs, 4-piston fixed caliper
Braking System Rear:
Single 265 mm disc, 2-piston floating caliper
Suspension Front:
BMW Telelever (or conventional upside-down forks depending on exact year/variant, R1200S used conventional)
Suspension Rear:
BMW Paralever (single-sided swingarm with adjustable shock absorber)
Passive Features
Lighting:
Halogen headlight, LED taillight, amber turn signals
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer and speedometer, LCD display for gear indicator, fuel level, trip computer, engine temperature, time, and warning lights. Options for heated grips, ABS indicators.
Driver Assistance
ABS System:
BMW Integral ABS, which combines braking actuation and can be partially or fully de-activated.
Traction Control:
Not standard on early R1200S models, but ASC (Automatic Stability Control) became available on later Boxer models. Check specific VIN for this feature.
Connectivity
Connectivity Features:
Limited factory connectivity by modern standards. Typically includes provision for diagnostic tools via OBD-II port or BMW proprietary connector.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km or annually, whichever comes first (refer to manual for precise intervals)
Valve Clearance Check Interval:
Every 20,000 km or 40,000 km (refer to manual for precise intervals and specifics)
Spark Plug Replacement Interval:
Every 40,000 km (refer to manual for exact intervals and plug type)
Fluid Specifications
Brake Fluid Type:
DOT 4 (refer to manual for specific BMW approval and replacement intervals)
Coolant Type:
BMW Approved Anti-freeze/Coolant (typically ethylene glycol based with corrosion inhibitors, refer to manual for specific formulation)
Clutch Fluid Type:
DOT 4 (same as brake fluid, refer to manual for specifics)
Known Issues
Common Wear Items:
Clutch slave cylinder seal leaks, driveshaft splines wear (if not properly greased), rear shock absorber damping degradation over time, potential ABS sensor issues.
Electrical Gremlins:
While generally reliable, some minor electrical issues can arise, often related to sensor connections or battery health. Manual is key for diagnostics.
Maintenance Tips
Preventative Maintenance:
Regularly inspect and grease driveshaft splines, monitor clutch fluid level, ensure battery is well-maintained, especially during storage.
📚 Vehicle History
Brand Heritage
Heritage Focus:
BMW Motorrad's long history of engineering excellence, boxer engines, shaft drive, and premium motorcycles since 1923.
Model Evolution
Predecessor:
BMW R1100S
Successor:
BMW R1200RS (introduced later, distinct evolution)
Production
Production Years:
2004-2008
Manufacturing Location:
Berlin, Germany (BMW Motorrad plant)
🏆 Awards & Recognition
Recognitions
Critical Acclaim:
Praised for its potent engine, sophisticated handling, and comfort for long-distance riding. Often cited as a benchmark sport-touring machine of its era.
Ratings
Reliability Perception:
Generally considered reliable with proper maintenance, consistent with BMW's reputation. Issues typically stem from neglected maintenance or component wear as expected with mileage.
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