BMW K1200 1997-2004 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: K1200 Model Variant: K1200 Series (e.g., K1200RS, K1200LT, K1200GT - manual likely covers shared components) Model Years Covered: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Codes Internal Model Codes: Likely covers K589 platform variants 👋 Introduction Market Position Brand Focus: BMW's premium touring and sport-touring motorcycle segment Competitive Analysis Segment Competitors: Competed against models like Honda ST1100/ST1300, Yamaha FJ1300, Kawasaki Concours. Key Features Vehicle Attributes: Known for its inline four-cylinder engine, shaft drive, sophisticated suspension, and comfort for long-distance touring. Variants offered different levels of equipment and comfort. Manual Value Target Audience: DIY mechanics, independent repair shops, and BMW K1200 owners seeking to maintain or repair their motorcycles. 📋 Manual Details Coverage Areas Major Systems: Engine, Fuel System, Drivetrain, Chassis, Electrical System, Bodywork, Suspension, Brakes, Cooling System, Exhaust System, Wheels & Tires, Instruments & Indicators Specific Models Within Series: Likely covers key components shared across K1200RS, K1200LT, and K1200GT variants, with model-specific variations noted where applicable. Page Count Estimated Pages: Estimate: 500-800 pages (typical for comprehensive workshop manuals covering multiple model years and variants) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (likely PDF), potentially printable 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, component inspection, tolerances, torque specifications, piston rings, crankshaft, camshafts, valve train, cylinder head, block Fuel System: Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel pressure regulator, fuel tank, lines, diagnostics Ignition System: Ignition coils, spark plugs, timing, electronic control unit (ECU) related ignition functions Drivetrain: Clutch operation, gearbox (transmission) overhaul, final drive (shaft drive) system, U-joints, rear differential Suspension: Front forks (telescopic), rear shock absorber, linkages, springs, damping adjustments, seals, bearings Brakes: Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake pads, rotors, ABS (if equipped), bleeding procedures Electrical System: Wiring diagrams, battery, starter, alternator, lighting, fuses, relays, sensors, ECU, CAN bus (if applicable), diagnostics of electrical faults Bodywork: Fairings, panels, seat, handlebars, fuel tank removal/installation, body trim Cooling System: Radiator, cooling fan, water pump, coolant hoses, thermostat, coolant specifications Exhaust System: Exhaust headers, mufflers, catalytic converter (if applicable), gaskets, mounting hardware Wheels Tires: Wheel bearing replacement, tire mounting/balancing, wheel specifications, recommended tire pressures Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, brake fluid flush, coolant flush, chain/shaft drive maintenance Troubleshooting: Diagnostic charts, fault code interpretation (if applicable), common problems and solutions for each system Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnostics and repair, fuel injection system servicing Component Replacement: Step-by-step instructions for replacing common wear items and major components Torque Specifications: Detailed torque values for all critical fasteners across all systems Special Tools: Identification of specialized tools required for specific procedures Technical Depth Depth Level: Comprehensive (from basic maintenance to complete engine and transmission rebuilds) 📊 Manual Specifications File Format Digital Format: PDF Print Quality Printability: Designed for high-quality printing of individual pages or sections Binding Type Digital Accessibility: Searchable text within PDF for quick information retrieval Paper Type Digital Content Quality: Contains diagrams, schematics, illustrations, and detailed text descriptions ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, 4-stroke Engine Displacement: 1171 cc (for early models, potentially 1170cc or 1172cc depending on exact variant) Bore X Stroke: Typical ~70.5 mm x 75.0 mm (verify for specific sub-models) Valve Train: DOHC, 4 valves per cylinder Performance Horsepower: Approx. 100-110 hp (depending on variant and tune) Torque: Approx. 110-120 Nm (depending on variant) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (95 RON recommended) Ignition System Ignition Type: Digital electronic ignition 🔧 Transmission Standard Transmission Type: 6-speed manual gearbox Features Drive Type: Shaft drive (enclosed) Fluid Specifications Gearbox Oil: BMW recommends specific gearbox oil (e.g., SAE 75W/90 GL-5). Consult manual for exact part number and capacity. 📐 Dimensions Exterior Wheelbase: Varies by model, typically around 1550-1650 mm Weights Dry Weight: Approx. 250-290 kg (depending on model) Gross Vehicle Weight: Approx. 450-500 kg (depending on model) 🛡️ Safety Features Ratings ABS: Optional ABS (BMW Motorrad ABS) available on many variants Active Features Braking System: Integral ABS (disables front brake lever for rear brake, and vice-versa on some systems) or conventional ABS 💡 Technology Features Infotainment Audio System: Optional integrated audio systems on LT models. Manual will likely cover radio, speakers, and controls. Cruise Control: Optional cruise control functionality on some variants. Manual will detail operation and troubleshooting. Driver Assistance ABS: BMW Motorrad ABS system, its operation, diagnostics, and maintenance. Connectivity Diagnostic Ports: Likely includes diagnostic connectors for BMW's proprietary diagnostic systems (e.g., I-Bus or similar for early models). 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000 km or annually, whichever comes first (refer to manual for precise recommendation) Valve Clearance Check: Every 20,000 - 30,000 km (refer to manual) Spark Plug...
BMW's premium touring and sport-touring motorcycle segment
Competitive Analysis
Segment Competitors:
Competed against models like Honda ST1100/ST1300, Yamaha FJ1300, Kawasaki Concours.
Key Features
Vehicle Attributes:
Known for its inline four-cylinder engine, shaft drive, sophisticated suspension, and comfort for long-distance touring. Variants offered different levels of equipment and comfort.
Manual Value
Target Audience:
DIY mechanics, independent repair shops, and BMW K1200 owners seeking to maintain or repair their motorcycles.
Diagnostic charts, fault code interpretation (if applicable), common problems and solutions for each system
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnostics and repair, fuel injection system servicing
Component Replacement:
Step-by-step instructions for replacing common wear items and major components
Torque Specifications:
Detailed torque values for all critical fasteners across all systems
Special Tools:
Identification of specialized tools required for specific procedures
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds)
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Printability:
Designed for high-quality printing of individual pages or sections
Binding Type
Digital Accessibility:
Searchable text within PDF for quick information retrieval
Paper Type
Digital Content Quality:
Contains diagrams, schematics, illustrations, and detailed text descriptions
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, 4-stroke
Engine Displacement:
1171 cc (for early models, potentially 1170cc or 1172cc depending on exact variant)
Bore X Stroke:
Typical ~70.5 mm x 75.0 mm (verify for specific sub-models)
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower:
Approx. 100-110 hp (depending on variant and tune)
Torque:
Approx. 110-120 Nm (depending on variant)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (95 RON recommended)
Ignition System
Ignition Type:
Digital electronic ignition
🔧 Transmission
Standard
Transmission Type:
6-speed manual gearbox
Features
Drive Type:
Shaft drive (enclosed)
Fluid Specifications
Gearbox Oil:
BMW recommends specific gearbox oil (e.g., SAE 75W/90 GL-5). Consult manual for exact part number and capacity.
📐 Dimensions
Exterior
Wheelbase:
Varies by model, typically around 1550-1650 mm
Weights
Dry Weight:
Approx. 250-290 kg (depending on model)
Gross Vehicle Weight:
Approx. 450-500 kg (depending on model)
🛡️ Safety Features
Ratings
ABS:
Optional ABS (BMW Motorrad ABS) available on many variants
Active Features
Braking System:
Integral ABS (disables front brake lever for rear brake, and vice-versa on some systems) or conventional ABS
💡 Technology Features
Infotainment
Audio System:
Optional integrated audio systems on LT models. Manual will likely cover radio, speakers, and controls.
Cruise Control:
Optional cruise control functionality on some variants. Manual will detail operation and troubleshooting.
Driver Assistance
ABS:
BMW Motorrad ABS system, its operation, diagnostics, and maintenance.
Connectivity
Diagnostic Ports:
Likely includes diagnostic connectors for BMW's proprietary diagnostic systems (e.g., I-Bus or similar for early models).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 km or annually, whichever comes first (refer to manual for precise recommendation)
Valve Clearance Check:
Every 20,000 - 30,000 km (refer to manual)
Spark Plug Replacement:
Every 20,000 - 30,000 km (refer to manual)
Fluid Specifications
Engine Oil Type:
Synthetic motorcycle oil, SAE 15W/50 or 20W/50 (API SG or higher). Consult manual for specific BMW approval (e.g., BMW Motorrad Approved). Capacity: Approx. 3.5-4.0 liters.
Coolant Type:
Ethylene glycol based coolant, 50/50 mix with distilled water. BMW recommends specific coolant. Capacity: Approx. 2.5-3.0 liters.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Known Issues
Common Wear Items:
Clutch wear, rear shock absorber damping, front fork seals, starter motor (on some units), electrical connectors.
Maintenance Tips:
Regular lubrication of shaft drive splines is crucial. Ensure proper bleeding of ABS systems if applicable.
📚 Vehicle History
Brand Heritage
Bmw Motorrad Legacy:
BMW has a long history of engineering robust and technologically advanced motorcycles, particularly in the touring segment.
Model Evolution
K Series Development:
The K1200 series represented a significant evolution of BMW's inline four-cylinder 'K' bike platform, known for its smooth power delivery and enclosed drivetrain.
Production
Manufacturing Location:
Germany
🏆 Awards & Recognition
Recognitions
Motorcycle Of The Year:
While specific awards are not listed in the product information, BMW motorcycles often receive positive reviews for engineering and touring capabilities in reputable motorcycle publications.
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