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BMW K1200RS Digital Workshop Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: K1200RS Vehicle Type: Motorcycle Category: Sport Tourer Codes Chassis Code: K589 👋 Introduction Market Position Vehicle Segment: Premium Sport Touring Motorcycle Target Audience: Owners and independent workshops seeking in-depth technical knowledge for maintenance and repair. Competitive Analysis Competitors: Honda VFR, Kawasaki GTR, Yamaha FJR, Ducati ST series Key Features Vehicle Strengths: Smooth power delivery, advanced technology (for its era), comfort for long distances. Manual Value Proposition: Provides comprehensive, manufacturer-level technical data essential for proper servicing and repair of a complex machine. 📋 Manual Details Coverage Areas Manual Type: Digital Workshop Repair Manual Language: English Format: Digital (likely PDF or similar e-book format) Page Count Estimated Page Count: Comprehensive (exact count not specified, but implied to be extensive for workshop repair) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, repair, and adjustment procedures for the entire engine assembly. Engine Management: Diagnosis and repair of the Motronic engine management system, fuel injection, ignition timing, and emission control. Transmission: Detailed procedures for the gearbox, clutch assembly, final drive, and associated components. Chassis And Frame: Inspection, maintenance, and repair of the frame, subframe, swingarm, and steering head bearings. Suspension: Front fork (Paralever) overhaul, rear shock absorber adjustment and replacement, and related components. Brakes: Complete brake system diagnosis, repair, and maintenance for both front and rear braking systems, including ABS. Electrical System: Wiring diagrams, diagnosis of electrical faults, component testing, battery, alternator, starter motor, lighting, and instrumentation. Fuel System: Fuel pump, injectors, fuel lines, and tank maintenance and repair. Cooling System: Radiator, coolant flow, water pump, and thermostat servicing. Exhaust System: Inspection and replacement of exhaust headers, mufflers, and catalytic converter. Bodywork And Fairings: Disassembly, reassembly, and repair of fairings, seat, fuel tank, and other cosmetic components. Wheels And Tires: Tire replacement, wheel balancing, and bearing maintenance. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, chain/driveshaft maintenance, brake fluid service. Troubleshooting: Diagnostic flowcharts and step-by-step troubleshooting for common and complex issues. Engine Rebuild: Complete engine disassembly, inspection, component replacement, and reassembly. Transmission Repair: Gearbox disassembly, clutch replacement, and final drive servicing. Electrical Diagnostics: Component testing, circuit diagnosis, and wiring harness repair. Suspension Overhaul: Fork seal replacement, damper adjustments, and shock absorber servicing. Brake System Service: Brake pad replacement, caliper service, bleeding procedures, and ABS module diagnostics. Bodywork Refurbishment: Fairing repair, panel alignment, and trim piece replacement. Technical Depth Diagnostic Capability: Advanced diagnostic procedures for engine management and electrical systems, including specific error codes. Repair Scope: Covers everything from minor adjustments to complete engine and gearbox rebuilds. Technical Data Precision: Includes precise torque specifications, clearances, tolerances, and fluid levels. 📊 Manual Specifications File Format File Type: Digital Document (e.g., PDF) Searchability: Likely searchable text for quick access to information. Print Quality Print Compatibility: Designed for digital viewing, but printable for workshop use. Binding Type Binding: Not applicable (digital format) Paper Type Paper Quality: Not applicable (digital format) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, inline four-cylinder Displacement: 1171 cc (71.6 cu in) Bore X Stroke: 77.6 mm x 64 mm (3.06 in x 2.52 in) Valve Train: DOHC, 4 valves per cylinder Performance Horsepower: 110 hp (82 kW) at 7500 rpm (approximate, depending on market and tune) Torque: 115 Nm (85 lb-ft) at 6000 rpm (approximate, depending on market and tune) Fuel System Fuel Delivery: Bosch Motronic electronic fuel injection Fuel Type: Unleaded premium gasoline (95 RON recommended) Fuel Capacity: 22 liters (5.8 US gal) Cooling System Cooling Method: Liquid-cooled Lubrication Oil Type: SAE 20W-40 or SAE 20W-50 motorcycle specific engine oil 🔧 Transmission Standard Transmission Type: 5-speed manual sequential gearbox Features Final Drive: Shaft drive Clutch Type: Wet multi-plate clutch, hydraulically operated Gear Ratios: Specific gear ratios available within the manual. 📐 Dimensions Exterior Length: Approx. 2,180 mm (85.8 in) Width: Approx. 810 mm (31.9 in) at handlebars Height: Approx. 1,320 mm (52.0 in) at seat height (adjustable) Weights Dry Weight: Approx. 245 kg (540 lbs) Wet Weight: Approx. 270 kg (595 lbs) (fully fueled) Load Capacity: Refer to manual for specific rider and luggage limits. 🛡️ Safety Features Ratings ABS: BMW Integral ABS (optional on early models, standard on later) Active Features Braking System: Hydraulic dual disc front brakes with 4-piston calipers, Single disc rear brake with 2-piston caliper. Lighting: Halogen headlight, LED tail light, turn signals. Passive Features Frame Construction: Aluminum composite frame for strength and rigidity. Ergonomics: Adjustable seat height and handlebar position for rider comfort. 💡 Technology Features Infotainment Instrumentation: Analog tachometer and speedometer, digital display for fuel level, gear indicator, clock, coolant temperature, trip meters, and warning lights. Driver Assistance ABS System: Integral ABS system featuring combined braking and optional anti-lock functionality. Connectivity Diagnostic Port: BMW specific diagnostic port for fault code retrieval and analysis. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000 km (6,000...
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Type: Motorcycle
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Sku: 262381
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BMW K1200RS Digital Workshop Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
K1200RS
Vehicle Type:
Motorcycle
Category:
Sport Tourer
Codes
Chassis Code:
K589
👋 Introduction
Market Position
Vehicle Segment:
Premium Sport Touring Motorcycle
Target Audience:
Owners and independent workshops seeking in-depth technical knowledge for maintenance and repair.
Competitive Analysis
Competitors:
Honda VFR, Kawasaki GTR, Yamaha FJR, Ducati ST series
Key Features
Vehicle Strengths:
Smooth power delivery, advanced technology (for its era), comfort for long distances.
Manual Value Proposition:
Provides comprehensive, manufacturer-level technical data essential for proper servicing and repair of a complex machine.
📋 Manual Details
Coverage Areas
Manual Type:
Digital Workshop Repair Manual
Language:
English
Format:
Digital (likely PDF or similar e-book format)
Page Count
Estimated Page Count:
Comprehensive (exact count not specified, but implied to be extensive for workshop repair)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, repair, and adjustment procedures for the entire engine assembly.
Engine Management:
Diagnosis and repair of the Motronic engine management system, fuel injection, ignition timing, and emission control.
Transmission:
Detailed procedures for the gearbox, clutch assembly, final drive, and associated components.
Chassis And Frame:
Inspection, maintenance, and repair of the frame, subframe, swingarm, and steering head bearings.
Suspension:
Front fork (Paralever) overhaul, rear shock absorber adjustment and replacement, and related components.
Brakes:
Complete brake system diagnosis, repair, and maintenance for both front and rear braking systems, including ABS.
Electrical System:
Wiring diagrams, diagnosis of electrical faults, component testing, battery, alternator, starter motor, lighting, and instrumentation.
Fuel System:
Fuel pump, injectors, fuel lines, and tank maintenance and repair.
Cooling System:
Radiator, coolant flow, water pump, and thermostat servicing.
Exhaust System:
Inspection and replacement of exhaust headers, mufflers, and catalytic converter.
Bodywork And Fairings:
Disassembly, reassembly, and repair of fairings, seat, fuel tank, and other cosmetic components.
Wheels And Tires:
Tire replacement, wheel balancing, and bearing maintenance.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, chain/driveshaft maintenance, brake fluid service.
Troubleshooting:
Diagnostic flowcharts and step-by-step troubleshooting for common and complex issues.
Engine Rebuild:
Complete engine disassembly, inspection, component replacement, and reassembly.
Transmission Repair:
Gearbox disassembly, clutch replacement, and final drive servicing.
Electrical Diagnostics:
Component testing, circuit diagnosis, and wiring harness repair.
Suspension Overhaul:
Fork seal replacement, damper adjustments, and shock absorber servicing.
Brake System Service:
Brake pad replacement, caliper service, bleeding procedures, and ABS module diagnostics.
Bodywork Refurbishment:
Fairing repair, panel alignment, and trim piece replacement.
Technical Depth
Diagnostic Capability:
Advanced diagnostic procedures for engine management and electrical systems, including specific error codes.
Repair Scope:
Covers everything from minor adjustments to complete engine and gearbox rebuilds.
Technical Data Precision:
Includes precise torque specifications, clearances, tolerances, and fluid levels.
📊 Manual Specifications
File Format
File Type:
Digital Document (e.g., PDF)
Searchability:
Likely searchable text for quick access to information.
Print Quality
Print Compatibility:
Designed for digital viewing, but printable for workshop use.
Binding Type
Binding:
Not applicable (digital format)
Paper Type
Paper Quality:
Not applicable (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, inline four-cylinder
Displacement:
1171 cc (71.6 cu in)
Bore X Stroke:
77.6 mm x 64 mm (3.06 in x 2.52 in)
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower:
110 hp (82 kW) at 7500 rpm (approximate, depending on market and tune)
Torque:
115 Nm (85 lb-ft) at 6000 rpm (approximate, depending on market and tune)
Fuel System
Fuel Delivery:
Bosch Motronic electronic fuel injection
Fuel Type:
Unleaded premium gasoline (95 RON recommended)
Fuel Capacity:
22 liters (5.8 US gal)
Cooling System
Cooling Method:
Liquid-cooled
Lubrication
Oil Type:
SAE 20W-40 or SAE 20W-50 motorcycle specific engine oil
🔧 Transmission
Standard
Transmission Type:
5-speed manual sequential gearbox
Features
Final Drive:
Shaft drive
Clutch Type:
Wet multi-plate clutch, hydraulically operated
Gear Ratios:
Specific gear ratios available within the manual.
📐 Dimensions
Exterior
Length:
Approx. 2,180 mm (85.8 in)
Width:
Approx. 810 mm (31.9 in) at handlebars
Height:
Approx. 1,320 mm (52.0 in) at seat height (adjustable)
Weights
Dry Weight:
Approx. 245 kg (540 lbs)
Wet Weight:
Approx. 270 kg (595 lbs) (fully fueled)
Load Capacity:
Refer to manual for specific rider and luggage limits.
🛡️ Safety Features
Ratings
ABS:
BMW Integral ABS (optional on early models, standard on later)
Active Features
Braking System:
Hydraulic dual disc front brakes with 4-piston calipers, Single disc rear brake with 2-piston caliper.
Lighting:
Halogen headlight, LED tail light, turn signals.
Passive Features
Frame Construction:
Aluminum composite frame for strength and rigidity.
Ergonomics:
Adjustable seat height and handlebar position for rider comfort.
💡 Technology Features
Infotainment
Instrumentation:
Analog tachometer and speedometer, digital display for fuel level, gear indicator, clock, coolant temperature, trip meters, and warning lights.
Driver Assistance
ABS System:
Integral ABS system featuring combined braking and optional anti-lock functionality.
Connectivity
Diagnostic Port:
BMW specific diagnostic port for fault code retrieval and analysis.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 km (6,000 miles) or annually, whichever comes first.
Major Service Interval:
Comprehensive service every 20,000 km (12,000 miles), including valve clearance checks.
Brake Fluid Change:
Every 2 years regardless of mileage.
Fluid Specifications
Engine Oil Capacity:
Approx. 4.0 liters (4.2 US quarts) with filter change.
Brake Fluid Type:
DOT 4
Coolant Type:
BMW approved coolant/antifreeze mixture (typically 50/50).
Final Drive Oil Type:
SAE 75W-90 synthetic hypoid gear oil.
Known Issues
Common Wear Items:
Clutch wear, fuel pump issues (especially with E10 fuel), alternator diode failures, and occasional ABS sensor faults.
Typical Repairs:
Fork seal replacement, wheel bearing replacement, brake caliper seal replacement.
📚 Vehicle History
Brand Heritage
Manufacturer:
Bayerische Motoren Werke AG (BMW)
Motorcycle Division History:
BMW has a long and distinguished history in motorcycle manufacturing dating back to the 1920s.
Model Evolution
K Series Introduction:
The K series, known for its inline-four engines and shaft drive, debuted in 1983 with the K100. The K1200RS evolved from this platform.
K1200Rs Introduction Years:
Introduced in 1997, succeeding the K1100RS.
Updates And Facelifts:
Received updates including improved ABS, revised fairing aerodynamics, and engine tuning over its production run.
Production
Production Years:
1997 - 2004
Manufacturing Location:
Berlin, Germany
🏆 Awards & Recognition
Recognitions
Sport Tourer Acclaim:
The K1200RS was generally well-received for its performance and touring capabilities, often lauded in contemporary motorcycle reviews.
Ratings
Reliability Perception:
Generally considered reliable with proper maintenance, though some electrical components and the fuel pump have been noted areas of potential concern.
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