BMW K 1200 RS 2004 Maintenance Instruction

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Maintenance Instructions (US Model)

K 1200 RS

BMW Motorrad

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Rider's Manual

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Summary of Contents for BMW K 1200 RS 2004

Page 1 Maintenance Instructions (US Model) K 1200 RS BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad BMW Motorrad On-board On-board On-board On-board On-board...
Page 2 Please note This symbol indicates pre- cautions and measures which are essential in protecting the rider or other persons from severe or fatal injury. Specific instructions and safety precautions intended to pre- vent damage to the motorcycle. Disregarding them may render the warranty invalid.
Page 3 Please do not hesitate to reasons. contact your authorized BMW Your BMW Motorrad retailer is motorcycle retailer on all best placed to keep you matters concerning your informed of the current content motorcycle.
Page 4 BMW cannot assess every sin- gle product of outside origin in order to decide whether it can be used on or with a BMW vehi- cle without constituting a safety risk. Nor is approval by an official...
Page 5 Maintenance work Maintenance work is divided up into Service, Inspection and Annual Service. BMW Inspection 600 miles (1,000 km) BMW Running-in Check after the first 600 miles (1,000 km). BMW Service After the first 6,000 miles (10,000 km) and every further 12,000 miles (20,000 km) (18,000 miles …, 30,000 miles …,...
Page 6 Maintenance confirmations BMW Service Pre-delivery check 10,000 km (6,000 miles) Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature BMW Inspection BMW Inspection 1,000 km...
Page 7 Confirmation of maintenance work BMW Service BMW Service 30,000 km 50,000 km (18,000 miles) (30,000 miles) Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature...
Page 8 Confirmation of maintenance work BMW Service BMW Service 70,000 km 90,000 km (42,000 miles) (54,000 miles) Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature...
Page 9 Confirmation of maintenance work BMW Service BMW Service 110,000 km 130,000 km (66,000 miles) (78,000 miles) Carried out in accordance with Carried out in accordance with manufacturer’s instructions manufacturer’s instructions Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature...
Page 10 Confirmation of maintenance work BMW Annual Service BMW Annual Service performed in accordance with performed in accordance with manufacturer’s instructions manufacturer’s instructions Brake fluid changed: Brake fluid changed: Wheel circuit/brake system - Wheel circuit/brake system - every year every year...
Page 11 Confirmation of maintenance work BMW Annual Service BMW Annual Service performed in accordance with performed in accordance with manufacturer’s instructions manufacturer’s instructions Brake fluid changed: Brake fluid changed: Wheel circuit/brake system - Wheel circuit/brake system - every year every year...
Page 12 Supplementary Service Record Record of all work performed in workshop Item Mileage Date The list is intended as a record of maintenance, warranty and repair work, the installation of accessories and, if appropriate, special campaign work.
Page 13 Supplementary Service Record Record of all work performed in workshop Item Mileage Date The list is intended as a record of maintenance, warranty and repair work, the installation of accessories and, if appropriate, special campaign work.
Page 14 Supplementary Service Record Record of all work performed in workshop Item Mileage Date The list is intended as a record of maintenance, warranty and repair work, the installation of accessories and, if appropriate, special campaign work.
Page 15 Supplementary Service Record Record of all work performed in workshop Item Mileage Date The list is intended as a record of maintenance, warranty and repair work, the installation of accessories and, if appropriate, special campaign work.
Page 16 Supplementary Service Record Odometer replaced Odometer replaced Odometer reading is not total Odometer reading is not total distance covered. distance covered. Odometer reading Odometer reading Date, stamp, signature Date, stamp, signature Odometer replaced Odometer replaced Odometer reading is not total Odometer reading is not total distance covered.
Page 17 General instructions Your motorcycle is equipped with Digital Motor Electronic (MOTRONIC) engine manage- ment and a high-power ignition If you intend to perform the system. maintenance and general care work described in the following section yourself, you must pos- sess the necessary knowledge Do not touch live parts while of technical matters and the engine is running or the...
Page 18 Remember: the safety and reli- ability of your motorcycle are the most important consider- ations. BMW refuses to accept liability You should therefore not for damage or consequential attempt any complex repair or damage due to repairs or ser- maintenance tasks.
Page 19 General instructions Technical modifications The data stored in the MOTRONIC control unit is the result of extensive experi- mental and testing work. Tampering with the MOTRONIC control unit rep- resents an increased safety risk for the rider. Tampering with the MOTRONIC control unit invalidates the war- ranty.
Page 20 Genuine BMW parts such modifications, comply with all the legal requirements. For reasons of safety, use only The motorcycle must not genuine BMW parts and infringe your national road-vehi- accessories. cle construction and use regu- Genuine BMW parts are lations.
Page 21 Troubleshooting chart Fault: Engine does not start at all or is very difficult to start Possible cause Remedy Page Wrong ignition key Ignition key in ON Rider’s Manual position position Chapter 1 Kill switch is off Move kill switch to Rider’s Manual center position Chapter 3...
Page 22 – not described on pages More detailed technical infor- 15 ... 60 – attended to by a mation is available in the follow- BMW-certified workshop, ing publications: preferably an – BMW Repair Manual authorized BMW Motorrad – BMW electrical circuit-dia- retailer. grams brochure...
Page 23 Removing the front wheel • Place the motorcycle on its main stand on a flat, firm sur- face Removing the front mud- guard • Remove 1 screw 2 at left and right Make sure that the motorcy- • Remove 1 screw 3 at left and cle is standing firmly and can- right not tip forward or to either...
Page 24 Removing the front wheel Removing brake calipers • Push the brake pads back a little by lightly rocking the brake calipers • Carefully take off the left and When removing, avoid damage right brake calipers 2 to brake pipes, brake disks, brake pads or the wheel rim (mask off with tape if neces- sary).
Page 25 • Slacken off axle clamp bolts 2 on the left and right • Raise the front wheel with front wheel stand, BMW special tool No. 36 3 970, or a suitable Removing the front wheel auxiliary stand, and support if...
Page 26 Removing the front wheel • Pull out quick-release axle 2, at the same time turning it slightly to the right • Remove spacers 3 and bear- ing cap 4 • Roll the front wheel forwards and out Mark the installed position on the tire and ABS toothed ring;...
Page 27 Fitting the front wheel Note the position marks on the tire or ABS toothed ring and the direction-of-rotation arrow on the tire. • Roll the front wheel in between the fork legs Fitting the front wheel • Clean and insert spacing bushing 2 and bearing cap 3 –...
Page 28 2 hand-tight at left and right • Remove front-wheel stand Always have the tightening • Compress the front fork firmly torques checked by a BMW- several times certified workshop, preferably an authorized BMW Motorrad retailer. Make sure that the motorcy-...
Page 29 Fitting the front wheel Always have the tightening torques checked by a BMW- Installing brake calipers certified workshop, • Carefully push brake caliper 2 preferably an authorized BMW over the brake disk at left and Motorrad retailer. right • Using 2 screws 1 per caliper,...
Page 30 Fitting the front wheel BMW Integral ABS: once as- sembly work on the brake cal- ipers has been completed, Installing the front mud- the brake lever has to be op- guard erated after the ignition has • Carefully install front...
Page 31 Removing the rear wheel Avoid damage to brake lines, brake disk, brake pads and wheel when removing. Do not damage the ABS sensor • Place the motorcycle on its cable, toothed ring or sensor. main stand on a flat, firm sur- Do not scratch the wheel when face forcing back the brake pads or...
Page 32 Removing the rear wheel Check the brake pads ( • Force back the brake pads by and have them replaced if nec- tilting the caliper carefully essary. • Carefully place brake caliper over the brake disk • Remove spacing washer 3 •...
Page 33 Fitting the rear wheel • Check that the wheel center- ing spigot and the wheel hub contact faces 3 are free from grease • Push spacing washer 3 on to Use only wheel studs with the wheel centering spigot length code “55”. Do not oil or •...
Page 34 Fitting the rear wheel • Hand-tighten central screw 1 with taper ring 2 • 4 Insert wheel studs 4 with taper rings 3 and tighten hand-tight, then tighten to the Make sure that bracket 5 for specified preload torque in a brake line is correctly posi- crosswise pattern tioned.
Page 35 Fitting the rear wheel Always have the security of the fasteners checked by a BMW- Motorcycle not equipped with certified workshop, preferably BMW Integral ABS : when an authorized BMW Motorrad assembly work has been retailer. completed, depress the brake...
Page 36 • Visually check brake pad For your safety, we recommend thickness having work on the brake sys- Minimum pad thickness: tem performed by a BMW-certi- The brake pads show clear fied workshop, preferably an signs of wear 1. authorized BMW Motorrad re- –...
Page 37 • If the wear indicator is in contact For your safety, we recommend with the opposing brake pad: having work on the brake sys- Have the brake pads chan- tem performed by a BMW-certi- ged by a BMW-certified fied workshop, preferably an workshop, preferably an authorized authorized BMW Motorrad BMW Motorrad retailer.
Page 38 Spray guard Adjusting the spray guard • Slacken screw 1 on the inside of the rear mudguard You can adjust the spray guard • Move spray guard 2 to the to suit load and/or weather con- desired position and carefully ditions.
Page 39 Information on changing bulbs Your vehicle has a high-beam/ low-beam bulb, a brake-light bulb/rear-light bulb, a parking- Your motorcycle is equipped light bulb, a bulb for the license- with Digital Motor Electronic plate light, and four bulbs for (MOTRONIC) engine manage- the turn indicators.
Page 40 Changing bulbs Tail light/brake light Switch off the ignition before • Remove 2 retaining screws 1 changing a bulb. • Pull rear light 2 to the rear to remove • Turn bulb socket 4 counter- clockwise to disengage and Do not touch the glass of new remove it from the rear light bulbs with your fingers.
Page 41 Changing bulbs • Place the motorcycle on its main stand License-plate light • 2 Take out 2 screws 1 • Pull license plate light 3 down to remove • Press back the spring wire Switch off the ignition before clip and remove the bulb 2 changing a bulb.
Page 42 Changing bulbs Front turn indicators Switch off the ignition before changing a bulb. • Place the motorcycle on its main stand Do not touch the glass of new • Take out retaining screw 1 bulbs with your fingers. Use a •...
Page 43 Changing bulbs • Turn bulb socket 5 counter- clockwise to disengage and remove it from the turn-indi- • Installation is the reverse of cator housing the removal procedure • Press bulb 4 into its socket and turn it counter-clockwise to release •...
Page 44 Changing bulbs Rear turn indicators • Place the motorcycle on its main stand • Take out retaining screw 1 • Take off the flashing turn indi- Switch off the ignition before cator glass 3 changing a bulb. • Press bulb 2 into its socket and turn it counter-clockwise to release.
Page 45 Changing bulbs Parking light • Working from in front, pull the bulb holder 1 down and out of Switch off the ignition before the headlamp housing changing a bulb. • Pull bulb 2 upwards out of the holder • Insert the new bulb in the holder Do not touch the glass of new –...
Page 46 Changing bulbs • Place the motorcycle on its main stand • Turn the steering to full left lock Headlight • Disengage retaining clip 1 on one side first, then the other, press down and disengage from cover 2 Switch off the ignition before •...
Page 47 Changing bulbs Tab 5 must point vertically up, • Attach plug housing 6 to bulb so that it can be inserted into connections recess 4. • Insert cover 2 • Engage retaining clip 1 on • Insert a new H7 bulb one side first, then the other, •...
Page 48 Changing bulbs High-beam headlight • Turn the steering to full left Switch off the ignition before lock changing a bulb. • Disengage retaining clip 1 on one side first, then the other, press down and disengage from cover 2 Do not touch the glass of new •...
Page 49 Changing bulbs When installing – Make sure that groove 7 (round) and groove 9 • Using a screwdriver, press in (rectangular) are correctly one retaining lug 11 at left and positioned right, and open up the bulb – Align groove 6 in such a way holder that it points toward guide 8 •...
Page 50 Use only fuses of the specified rating and type. If a fuse blows repeatedly, have Replacing fuses the electrical system checked • Place motorcycle on main by a specialized workshop, (center) stand preferably an authorized BMW • Remove the dual seat motorcycle retailer!
Page 51 Fuses 8 Instrument cluster, control unit fuel warning Fuse assignment lamp, fan relay ....4 A Fuse box 1 Fuse box 2 1 Engine electronics ..10 A 1 Fan relay, 2 Fuel pump, injection valves, fan left and right ... 10 A oxygen sensor, diagnosis 2 Cruise control ....
Page 52 Battery safety instructions Gel batteries are maintenance- free. Compliance with the Do not attempt to jump-start instructions below is important the motorcycle using the on- in order to maximize battery life: board socket – Risk of fire! • Push-start the motorcycle only when the engine is –...
Page 53 In case of doubt ask a special- tery to run flat. If this happens, ist, preferably an authorized warranty claims will not be BMW motorcycle retailer , to accepted. prepare the vehicle for storing Disconnect the ground lead and to carry out the necessary...
Page 54 Battery Removing the battery Disconnecting the battery de- letes all entries (e.g. faults, set- tings) stored in the Motronic control unit's memory. Avoid damage to fuel tank, Loss of settings can temporarily wiring and hoses during impair the operating character- removal work.
Page 55 Battery • Disconnect negative battery lead 1 and swing it away from the negative post of the bat- tery or insulate it • Swing up protective cap 4 at the positive post Note rubber elements 5 on left • Disconnect positive battery and right.
Page 56 Battery Installing the battery Make sure that guard 7 is cor- rectly positioned. Before connecting the bat- Make sure that brake fluid tery, switch off the ignition. hoses 8, 9 are correctly rout- To avoid short-circuits: ed to avoid rubbing. •...
Page 57 Cleaning/care Aggressive or deep-action cleaning products and solvents should not be used to clean rubber and plastic parts; they may cause damage. Correct and regular cleaning of Do not use steam or pressure the battery is an important fac- cleaners. tor in maintaining the value of High water pressure can dam- your motorcycle.
Page 58 • For cleaning and care of fair- the approved care products ing elements and body pan- els, only use products from the BMW Cleaning and Care After cleaning or before start- • Do not clean the instrument ing a journey, always test the cluster, switches or windshield brakes.
Page 59 Cleaning/care Removing road salt • Wash the motorcycle down Cleaning the windshield immediately with cold water at • Clean off dirt and insects with the end of the journey a soft sponge and plenty of water Do not use warm water; this in- tensifies the effect of the salt.
Page 60 Cleaning/care Cleaning chrome-plated Repairing damage to the parts paintwork • Use a BMW paint pen to repair minor damage to the paintwork Treat chrome-plated parts reg- ularly with suitable care prod- ucts. Comply with the manufacturer's • Apply a wax-based corrosion-...
Page 61 BMW-certified workshop, able lubricant preferably your authorized • Coat bright metal/chrome- BMW Motorrad retailer.
Page 62 Starting Restoring to use • If necessary, remove protec- • Perform safety checks tive wax coating (Rider's Manual Chapter 2) • Clean the motorcycle ( • Check brakes • Install a charged battery ( (Rider' Manual Chapter 2) • Apply the correct grease to •...
Page 63 Engine 72 kW** 96 kW Engine, type Water-cooled inline four-cylinder engine, longitudinal and horizontal installation, with 4 valves per cylin- der, bucket-type tappets, two chain-driven overhead camshafts and wet sump lubrication. Displacement 1,171 cc 1,171 cc Max. nominal power output acc. to 95/1/EC 72 kW 96 kW at engine speed...
Page 64 Transmission Clutch Single dry plate with over-center action diaphragm spring and starter ring gear, mounted on crankshaft. Hydraulic release Effort at handlebar lever 95 N. Clutch plate Ø 7.09 in (180 mm) Manual transmission 6-speed with claw shift and integral torsional vibration damper Total spread of gear ratios 1st gear = 3.863 2nd gear = 3.022...
Page 65 Sintered metal brake pads Note color coding ( Rear brake Hydraulically operated disk brake with 2-piston fixed caliper and stainless-steel brake disk. Brake pads made from organic material Brake system BMW Integral ABS, partially integral...
Page 66 Frame and suspension Wheel control Front Telelever, leading link with central spring strut, pivoted centrally on main frame; no anti-dive Rear Cast aluminum single swinging arm with additional torque reac- tion strut to compensate for shaft drive effects (Paralever); swinging arm with off-center spring strut Front wheel suspension Gas-filled spring/damper strut, no...
Page 67 Frame and suspension Front steering angle 2 x 30° Front wheel caster offset - in normal-load position 4.88 in (124 mm) Tire tread depth (recommended minimum) Front wheel 0.08 in (2 mm) Rear wheel 0.12 in (3 mm) Observe the legally stipulated minimum tread depth.
Page 68 Frame and suspension Wheels and tires BMW cast-aluminum wheels with 5 double-spoke design, low aspect-ratio tires Front wheel Angled rim shoulder and double tire retaining hump Tire size and designation 3.50 x 17” Tire size and designation 120/70 ZR 17...
Page 69 “Special Oils” are approved individually by BMW AG and avail- able from your authorized BMW Motorrad retailer. All engine oils supplied by BMW are subject to regular BMW quality assurance checks. BMW does not approve the use of any upper-cylinder lubricants or similar oil additives.
Page 70 Castrol EPX 90, or SAE 90 API Fuel grade Super (premium) unleaded fuel to DIN 51 607 standard, minimum octane number 95 (RON) or 85 (MON), AKI 91 Premium Fuel tank capacity 5.54 gal (21 l) including approx. 1.06 gal (4 l) reserve BMW recommends Castrol...
Page 71 374 °F, high corrosion protection, good resistance to water and oxidation; e.g. Shell Retinax EP2 Brake fluid DOT 4 We recommend BMW brake fluids Use only new brake fluid to DOT 4 specification. Coolant Brand-name long-life antifreeze and corrosion inhibitor,...
Page 72 Electrical system Battery BMW Mareg 12 V 19 Ah or Gel battery, 12 V 19 Ah maintenance-free Spark plugs Approved makes/types Bosch XR7 LDC +/-0.004 +/-0.1 Electrode gap 0.03 in (0.8 Wear limit 1.0 mm (0.04 in) Fuses “Minifuse” flat-socket fuses...
Page 73 Dimensions and weights Overall length 88.58 in (2,250 mm) Width over handlebars (without vibration dampers) 26.77 in (680 mm) across front footrests 27.2 in (691 mm) across rear footrests 31.6 in (802 mm) Overall height (windshield lowered) 49.13 in (1,248 mm) Seat height, unladen 30.3/31.5 in (770/800 mm) weight...
Page 74 Performance data 72 kW** 96 kW Maximum speed acc. to type approval test more than 124 mph (more than 200 km/h) Elasticity 4th gear 50-75 mph 2.8 s 3.0 s (80-120 km/h) 5th gear 50-75 mph 3.4 s 3.8 s (80-120 km/h) 6th gear 50-75 mph 4.3 s...
Page 75 Cleaning/care Safety instructions, 50 Chrome, 58 Technical Data, 70 General notes, 55, 57 Warranty, 50 Paintwork damage, 58 BMW Integral ABS, 63 Road salt, 57 Bore/stroke, 61 Washing, 56 Brake caliper, installing Clutch, 62 Front wheel, 27 Compression ratio, 61...
Page 76 F – R Frame, 63 Maintenance confirmations, 4 Front mudguard Manual transmission Installing, 28 Capacity, 68 Removing, 21 Technical Data, 62 Front wheel Maximum engine speed, 61 Fitting, 25, 27 Maximum speed, 72 Removal, 21, 22, 23, 24 Motorcycle Technical Data, 66 Laying up, 59 Front wheel stand, 23, 26 Restoring to use, 60...
Page 77 S – Z Transmission Safety information, 2 Capacity, 68 Safety instructions, 15, 37 Oil types, 68 Explanation, 82 Technical Data, 62 Seat height, 71 Total spread of gear ratios, 62 Service, notes, 3 Tread depth, 65 Spark plugs, 70 Treatment of chrome-plated Speed limitations, 61 parts, 58 Spray guard, 36...
Page 78 Motorcycle data / Retailer data Motorcycle data Model Frame no. Color no. First registered on Registration no. Retailer data Person to contact for Service work Ms./Mr. Tel. no. Retailer’s address with telephone no. (company stamp)
Page 79 No claims will be Errors and omissions excepted. entertained as a result of such dis- © 2004 BMW Motorrad crepancies. Not to be reproduced either wholly Dimensions, weights, fuel con- or in part without written permis-...
Page 80 BMW recommends Castrol BMW Motorrad Printed information Order No.: 01 47 7 690 837 05.2004 The Ultimate 3rd edition US / RF Driving Machine...

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