BMW K1200RS K 1200 RS 2003 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: K1200RS Year: 2003 Codes Engine Code: K589 Generation Generation: Second Generation K1200RS (E42) 👋 Introduction Market Position Positioning: The BMW K1200RS (2003) was positioned as a high-performance sport touring motorcycle, blending the power of a sportbike with the comfort and amenities for long-distance travel. It was a premium offering in the motorcycle market. Competitive Analysis Competitors: Competed with other premium sport-touring motorcycles such as the Honda VFR800/VFR1200, Yamaha FJR1300, and Kawasaki GTR1400 (later models). Key Features Engine Configuration: Inline four-cylinder engine, a hallmark of the K-series, mounted longitudinally. Power And Performance: Delivered strong horsepower and torque figures for exhilarating acceleration and relaxed cruising. Ergonomics: Designed for rider comfort on long journeys, with adjustable ergonomics and wind protection. Technology: Featured advanced BMW technology, including integral ABS and a shaft drive system. 📋 Manual Details Coverage Areas Engine: Yes Transmission: Yes Chassis: Yes Electrical System: Yes Fuel System: Yes Braking System: Yes Suspension: Yes Bodywork: Yes Maintenance Procedures: Yes Troubleshooting: Yes Diagnostics: Yes Wiring Diagrams: Yes Page Count Estimated Pages: Hundreds (Specific count not provided in product description, but typical for factory manuals of this scope) Manual Type Type: Factory Service Repair Manual Language Language: English (Assumed based on common availability of BMW factory manuals) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Management: Detailed coverage of Motronic engine management, ignition, fuel injection, and emission control systems. Power Delivery: Complete information on the 5-speed transmission, clutch operation, and final drive (shaft drive). Braking And ABS: In-depth details on the integral ABS braking system, including component testing, bleeding procedures, and hydraulic circuits. Suspension And Steering: Coverage of the Telelever front suspension and Paralever rear suspension, including adjustments, servicing, and fork seal replacement. Electrical And Lighting: Comprehensive electrical diagrams, fuse box locations, battery maintenance, lighting system servicing, and instrumentation. Fuel And Exhaust: Details on fuel tank, fuel pump, injectors, and exhaust system components. Frame And Body: Information on frame inspection, body panel removal and installation, seat mechanisms, and fairing components. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug servicing, chain/shaft drive lubrication, and general inspection points. Major Repairs: Engine rebuild procedures, transmission overhauls, clutch replacement, and suspension component rebuilds. Troubleshooting Guides: Systematic diagnostic flowcharts and symptom-based troubleshooting for common and complex issues. Component Removal And Installation: Step-by-step instructions for removing, inspecting, repairing, and reinstalling all major components. Torque Specifications: Precise torque values for all critical fasteners to ensure correct assembly and prevent damage. Special Tool Requirements: Identification of any specialized tools or equipment needed for specific procedures. Technical Depth Depth: Comprehensive, covering everything from basic owner maintenance checks to full engine and transmission rebuilds, including advanced electrical diagnostics. 📊 Manual Specifications File Format Format: PDF Print Quality Quality: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: Liquid-cooled, four-stroke, inline four-cylinder Displacement: 1171 cc (71.4 cu in) Bore X Stroke: 79 mm x 59 mm Compression Ratio: 11.5:1 Valve Train: DOHC, 4 valves per cylinder Performance Horsepower: 110 hp (81 kW) @ 7500 rpm (approximate) Torque: 117 Nm (86 lb-ft) @ 6000 rpm (approximate) Fuel System Induction: Electronic fuel injection (Bosch Motronic MA 2.4) Fuel Type: Unleaded premium gasoline (95 RON recommended) Lubrication Oil Type: SAE 20W-40 motorcycle oil (API SG or higher) Oil Capacity: Approximately 4.0 liters (4.2 US quarts) with filter change. 🔧 Transmission Standard Type: 5-speed manual gearbox Clutch: Hydraulically operated, multi-plate wet clutch Features Drive System: Shaft drive to rear wheel Fluid Specifications Transmission Oil: SAE 75W-90 synthetic hypoid gear oil (API GL-5) 📐 Dimensions Exterior Length: Approx. 2,230 mm (87.8 in) Width: Approx. 850 mm (33.5 in) at handlebars Height: Approx. 1,430 mm (56.3 in) at handlebars Weights Dry Weight: Approx. 244 kg (538 lbs) Wet Weight: Approx. 266 kg (586 lbs) (fully fueled) Gross Vehicle Weight Rating: 480 kg (1,058 lbs) 🛡️ Safety Features Ratings ABS: Integral ABS (Anti-lock Braking System) - Standard Active Features Braking System: Dual 320 mm front discs with 4-piston calipers, Single 265 mm rear disc with 2-piston caliper. Integrated ABS system. Passive Features Lighting: Halogen headlights for excellent nighttime visibility. Chassis Stability: Designed for stable handling due to balanced weight distribution and advanced suspension. 💡 Technology Features Infotainment Instrumentation: Comprehensive analog tachometer and speedometer, digital display for gear selection, fuel level, clock, trip meters, and warning lights. Optional heated grips indicators. Driver Assistance ABS: BMW Integral ABS, providing combined braking and anti-lock functionality for enhanced safety. Connectivity Diagnostic Port: OBD-II compliant diagnostic port for connecting advanced diagnostic tools (typically found under the seat or near the battery). Comfort Features Heated Grips: Standard feature on most K1200RS models for rider comfort in cooler conditions. Windscreen: Adjustable windscreen for optimal wind deflection and rider comfort....
The BMW K1200RS (2003) was positioned as a high-performance sport touring motorcycle, blending the power of a sportbike with the comfort and amenities for long-distance travel. It was a premium offering in the motorcycle market.
Competitive Analysis
Competitors:
Competed with other premium sport-touring motorcycles such as the Honda VFR800/VFR1200, Yamaha FJR1300, and Kawasaki GTR1400 (later models).
Key Features
Engine Configuration:
Inline four-cylinder engine, a hallmark of the K-series, mounted longitudinally.
Power And Performance:
Delivered strong horsepower and torque figures for exhilarating acceleration and relaxed cruising.
Ergonomics:
Designed for rider comfort on long journeys, with adjustable ergonomics and wind protection.
Technology:
Featured advanced BMW technology, including integral ABS and a shaft drive system.
📋 Manual Details
Coverage Areas
Engine:
Yes
Transmission:
Yes
Chassis:
Yes
Electrical System:
Yes
Fuel System:
Yes
Braking System:
Yes
Suspension:
Yes
Bodywork:
Yes
Maintenance Procedures:
Yes
Troubleshooting:
Yes
Diagnostics:
Yes
Wiring Diagrams:
Yes
Page Count
Estimated Pages:
Hundreds (Specific count not provided in product description, but typical for factory manuals of this scope)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English (Assumed based on common availability of BMW factory manuals)
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Management:
Detailed coverage of Motronic engine management, ignition, fuel injection, and emission control systems.
Power Delivery:
Complete information on the 5-speed transmission, clutch operation, and final drive (shaft drive).
Braking And ABS:
In-depth details on the integral ABS braking system, including component testing, bleeding procedures, and hydraulic circuits.
Suspension And Steering:
Coverage of the Telelever front suspension and Paralever rear suspension, including adjustments, servicing, and fork seal replacement.
Electrical And Lighting:
Comprehensive electrical diagrams, fuse box locations, battery maintenance, lighting system servicing, and instrumentation.
Fuel And Exhaust:
Details on fuel tank, fuel pump, injectors, and exhaust system components.
Frame And Body:
Information on frame inspection, body panel removal and installation, seat mechanisms, and fairing components.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug servicing, chain/shaft drive lubrication, and general inspection points.
Systematic diagnostic flowcharts and symptom-based troubleshooting for common and complex issues.
Component Removal And Installation:
Step-by-step instructions for removing, inspecting, repairing, and reinstalling all major components.
Torque Specifications:
Precise torque values for all critical fasteners to ensure correct assembly and prevent damage.
Special Tool Requirements:
Identification of any specialized tools or equipment needed for specific procedures.
Technical Depth
Depth:
Comprehensive, covering everything from basic owner maintenance checks to full engine and transmission rebuilds, including advanced electrical diagnostics.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Quality:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Type:
Liquid-cooled, four-stroke, inline four-cylinder
Displacement:
1171 cc (71.4 cu in)
Bore X Stroke:
79 mm x 59 mm
Compression Ratio:
11.5:1
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower:
110 hp (81 kW) @ 7500 rpm (approximate)
Torque:
117 Nm (86 lb-ft) @ 6000 rpm (approximate)
Fuel System
Induction:
Electronic fuel injection (Bosch Motronic MA 2.4)
Fuel Type:
Unleaded premium gasoline (95 RON recommended)
Lubrication
Oil Type:
SAE 20W-40 motorcycle oil (API SG or higher)
Oil Capacity:
Approximately 4.0 liters (4.2 US quarts) with filter change.
🔧 Transmission
Standard
Type:
5-speed manual gearbox
Clutch:
Hydraulically operated, multi-plate wet clutch
Features
Drive System:
Shaft drive to rear wheel
Fluid Specifications
Transmission Oil:
SAE 75W-90 synthetic hypoid gear oil (API GL-5)
📐 Dimensions
Exterior
Length:
Approx. 2,230 mm (87.8 in)
Width:
Approx. 850 mm (33.5 in) at handlebars
Height:
Approx. 1,430 mm (56.3 in) at handlebars
Weights
Dry Weight:
Approx. 244 kg (538 lbs)
Wet Weight:
Approx. 266 kg (586 lbs) (fully fueled)
Gross Vehicle Weight Rating:
480 kg (1,058 lbs)
🛡️ Safety Features
Ratings
ABS:
Integral ABS (Anti-lock Braking System) - Standard
Active Features
Braking System:
Dual 320 mm front discs with 4-piston calipers, Single 265 mm rear disc with 2-piston caliper. Integrated ABS system.
Passive Features
Lighting:
Halogen headlights for excellent nighttime visibility.
Chassis Stability:
Designed for stable handling due to balanced weight distribution and advanced suspension.
💡 Technology Features
Infotainment
Instrumentation:
Comprehensive analog tachometer and speedometer, digital display for gear selection, fuel level, clock, trip meters, and warning lights. Optional heated grips indicators.
Driver Assistance
ABS:
BMW Integral ABS, providing combined braking and anti-lock functionality for enhanced safety.
Connectivity
Diagnostic Port:
OBD-II compliant diagnostic port for connecting advanced diagnostic tools (typically found under the seat or near the battery).
Comfort Features
Heated Grips:
Standard feature on most K1200RS models for rider comfort in cooler conditions.
Windscreen:
Adjustable windscreen for optimal wind deflection and rider comfort.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,000 miles) or annually, whichever comes first. (Consult manual for exact BMW recommendations).
Major Service Interval:
Typically every 20,000 km (12,000 miles), including valve clearance checks, spark plug replacement, and thorough inspection of major systems. (Consult manual for exact BMW recommendations).
Fluid Specifications
Coolant:
BMW approved ethylene glycol-based coolant concentrate mixed with distilled water (50:50 ratio).
Brake Fluid:
DOT 4 brake fluid
Final Drive Oil:
SAE 75W-90 synthetic hypoid gear oil (API GL-5)
Known Issues
Common Wear Items:
Front fork seals, clutch slave cylinder seal, fuel pump O-ring, and rear shock absorber (depending on mileage and usage). ABS modulator can sometimes develop issues.
Common Issues
Electrical Connections:
Corrosion in electrical connectors, particularly on the lighting and sensor circuits, can lead to intermittent faults.
Fuel System Maintenance:
Periodic cleaning or replacement of fuel injectors may be necessary for optimal performance, especially with varied fuel quality.
📚 Vehicle History
Brand Heritage
Heritage:
BMW Motorrad has a long-standing reputation for engineering excellence, innovation, and building durable, high-performance motorcycles, particularly known for their boxer engines and later, their inline-four K-series.
Model Evolution
K Series Introduction:
The K-series, introduced in 1983 with the K100, represented BMW's move into liquid-cooled, transverse inline-four engines, though the K1200RS features a longitudinal orientation.
K1200Rs Development:
The K1200RS evolved from earlier K-series models, incorporating advancements in engine technology, chassis design, and rider ergonomics to create a more powerful and refined sport-touring machine. The 2003 model is part of the second generation, often referred to by its internal code E42.
Production
Production Period:
The K1200RS model line was produced from 1997 to 2004. The 2003 model year falls within this established production run.
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