BMW k 1200 rs Repair Manual
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BMW k 1200 rs Repair Manual

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Table of Contents

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Repair Manual
K 1200 RS
BMW Motorrad
After Sales

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Table of Contents

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Summary of Contents for BMW k 1200 rs

  • Page 1 Repair Manual K 1200 RS BMW Motorrad After Sales...
  • Page 2 Issued by © BMW Motorrad After Sales UX-VS-2 All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission. Errors and omissions excepted; subject to technical amendment. Printed in Germany 03/01 Order number 01 79 0 137 531...
  • Page 3 A new issue of this repair manual will be published if amendments or additions (supplements) are needed. All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification.

  • Page 4: Tightening Torques

    The list of contents is followed by the Technical Data table. Key to symbols In this Repair Manual for the K 1200 RS model, the following symbols are used; their meanings are ex- plained in the table. Special instructions aimed at improving the work procedures...
  • Page 5 Read out the fault memory BMW MoDiTeC unit [Integral ABS] perform bleed test with BMW MoDiTeC Check throttle cable play, adjust if necessary Change engine oil while at operating temperature If the motorcycle is ridden only for short distances or at outside temperatures below 0 °C (32 °F), this work must be...

  • Page 6: Pre-Delivery Check

    BMW Motorrad Pre-delivery check K 1200 RS as of model year 01, Integral ABS Customer Licence plate No. Pre-delivery check Order No. Mechanic’s signature Check the shipping crate for damage Unpacking the motorcycle – unpack – inspect for damage –...

  • Page 7: Engine

    BMW Motorrad Service data K 1200 RS as of model year 01, Integral ABS Unit of measure- Item Desired value ment Oil capacities Engine (with filter) 3.5 (6.2) litres (Imp. pints) Gearbox Initial filling about 0.6 (1 .0) litres (Imp. pints)

  • Page 8: 12 Engine Electrics

    Contents << Back Group / Chapter 00 Tightening torques, operating fluids 00 Pre-delivery check 00 Maintenance 11 Engine 12 Engine electrics 13 Fuel preparation and control 16 Fuel tank and lines 17 Radiator 18 Exhaust system 21 Clutch 23 Gearbox 31 Front forks 32 Steering >>...
  • Page 9 >> Continuation Group / Chapter 33 Rear wheel drive 34 Brake 36 Wheels and tyres 46 Frame 51 Equipment 52 Dualseat 61 General electrical equipment 62 Instruments 63 Lights << Back...

  • Page 10: Table Of Contents

    00 Tightening torques, operating fluids Contents Page Tightening torques ........................3 11 Engine ............................3 12 Engine electrics ........................4 13 Fuel preparation and control ....................5 16 Fuel tank and lines ........................5 17 Radiator ............................6 18 Exhaust system .........................6 21 Clutch ............................6 23 Transmission ..........................7 31 Front fork ............................8...
  • Page 11 Contents Page 00.2...

  • Page 12: Tightening Torques

    Tightening torques Model K 1200 RS Connection 11 Engine Cylinder head Cylinder head bolts 20 Oiled before installation Wrench angle ° Cylinder head cover Temperature sensor Coolant stub pipe Shield plate Split conrods Split-conrod bearing cap Wrench angle ° Engine block...

  • Page 13: Engine Electrics

    Model K 1200 RS Connection 11 Engine Timing chain Slider rail to camshaft bearing cap Timing case cover Chain tensioner to cover of timing case Screw plug for chain tensioner Timing case cover Oil/water pump Oil pressure switch to oil pump intermediate flange...

  • Page 14: Fuel Preparation And Control

    Model K 1200 RS Connection 12 Engine electrics Starter motor Starter motor to gearbox, M6 Positive lead to starter motor, M6 Earth (ground) lead to cross-tube Model K 1200 RS Connection 13 Fuel preparation and control Temperature sensor to intake air silencer...

  • Page 15: 17 Radiator

    Model K 1200 RS Connection 17 Radiator Expansion tank to frame Fan to radiator 2 Clean thread + Loctite 243 Coolant hose clips hand-tight Model K 1200 RS Connection 18 Exhaust system Exhaust system to cylinder head Retaining hoop to silencer (muffler)

  • Page 16: 23 Transmission

    Model K 1200 RS Connection 23 Transmission Housing Oil drain plug Oil filler plug Housing cover to housing Gearshift linkage Selector lever to selector shaft Gearshift pedal to transverse tube 8 Staburags NBU 30 PTM pivot bushing Gearshift lever, M6, adjustable...

  • Page 17: 31 Front Fork

    Model K 1200 RS Connection 31 Front fork Fork leg Oil drain plug, sliding tube Screw plug in fixed tube Leading link Leading link to sliding tube bridge 130 Clean thread and Loctite 2701 Leading link to frame 107 Clean thread and Loctite 243...

  • Page 18: 32 Steering

    Model K 1200 RS Connection 32 Steering Fastener for brake lever fitting Fastener for clutch lever fitting Cover for cable guide Pivot screw, handlebar lever Clean thread and Loctite 243 Model K 1200 RS Connection 33 Rear wheel drive Rear wheel drive...

  • Page 19: Brakes [Integral Abs]

    Model K 1200 RS Connection 34 Brakes [Integral ABS] Front brake Brake caliper to fork tube Grub screw in front brake caliper Brake disc to front wheel 21 Clean thread and Loctite 243 Brake hose/line/banjo bolt Brake fluid distributor to holder...

  • Page 20: Brakes [Optional Extras, Without Integral Abs]

    Model K 1200 RS Connection 34 Brakes [Optional extras, without Integral ABS] Front brake Brake caliper to fork tube Brake disc to front wheel 21 Clean thread and Loctite 243 Brake hose/line/banjo bolt Brake fluid distributor to holder Holder to sliding tube...
  • Page 21 Model K 1200 RS Connection 46 Frame Fairing Front mudguard, front (with rear section) to upper sliding tube Fairing holder Oil cooler to fairing bracket Fairing bracket, left/right, to frame Centre fairing bracket to frame Windscreen mount 6 Staburags NBU 30 PTM...

  • Page 22: Frame

    Model K 1200 RS Connection 46 Frame Rear frame Rear of frame to main frame, top Rear of frame to main frame, bottom Battery carrier to rear of frame, right Fuse box holder Seat tray support Grab handle Lock mount...

  • Page 23: 61 General Electrical Equipment

    Model K 1200 RS Connection 61 General electrical equipment Horn to fairing bracket Ground (earth) strap to engine block Electrics box to main frame Cables to main frame Temperature sensor to cylinder head Fastener, side stand switch, M6 5 Clean thread and Loctite 243...

  • Page 24: Table Of Operating Fluids

    Table of operating fluids Item Order number Quantity Lubricant Staburags NBU 30 PTM High-performance lubricating paste 07 55 9 056 992 75 g tube Optimoly MP 3 High-performance lubricating paste 07 55 9 062 476 100 g tube Optimoly TA High-temperature assembly paste 18 21 9 062 599 100 g tube Silicone grease 300, heavy...
  • Page 25 83 19 9 407 855 500 ml spray housings Crack testing agent for aluminium Developer MR 70 81 22 9 407 495 500 ml spray housings Installation aid BMW chilling spray Cooling spray 83 19 9 407 762 300 ml spray 00.16...
  • Page 26 00 Pre-delivery check Contents Page General view of crated motorcycle ..................19 Checking the shipping crate for damage ..............20 Damage discovered in Germany ....................20 Damage discovered in importer markets ................20 Unpacking the motorcycle ....................21 General instructions .........................21 Pushing the motorcycle onto a workshop platform ............21 Inspecting motorcycle for damage ..................21...
  • Page 27 Contents Page Adjusting footrests left/right .....................28 Adjusting gearshift lever ......................28 [Integral ABS] Performing bleed test with BMW MoDiTeC .........29 Final inspection and function check ................29 Final cleaning ..........................29 Handover ............................30 00.18...

  • Page 28: General View Of Crated Motorcycle

    General view of crated motorcycle 00.19...

  • Page 29: Checking The Shipping Crate For Damage

    Checking the shipping crate for 00 00 damage • When the motorcycle arrives, check the crate im- mediately for damage and if necessary examine the contents for consequential damage. Damage discovered in Germany 00 00 • Note the damage on the delivery slip. •...

  • Page 30: Unpacking The Motorcycle

    Cut the plastic sheet open and pull it off. Check for damage. • • Take out the separate pack of items: “Express message” to – Windscreen BMW Motorrad, UX-VS-1 – Mirrors, right/left Fax number 089-382-33220 • – Engine spoiler Rectify the fault.

  • Page 31: Installing Remaining Items On Motorcycle

    K41UB0020 Installing remaining items on Installing mirrors, left/right 00 00 00 00 motorcycle Installing the windscreen 00 00 Note: The windscreen can be set manually to two posi- tions. • Raise the windscreen holder. • Push the bushings (arrows) into the holes at the sides of the windscreen (1).

  • Page 32: Installing Bracket For Engine Spoiler

    Installing bracket for engine Installing the engine spoiler 00 00 00 00 spoiler KR460110 KR460120 • Secure the engine spoiler to the lower bracket. • • Fit the rubber support (1). Secure the engine spoiler to the left and right •...

  • Page 33: Filling And Charging The Battery

    Filling and charging the battery 00 00 Remove the battery Filling and charging the battery • Pull off the battery breather hose (3). Warning: Battery sulphuric acid ......Density 1.28 Battery acid is highly caustic. • Protect your eyes, face, hands, clothing and the Top up the battery acid to the MAX mark.

  • Page 34: Checking Tyre Pressures

    Checking tyre pressures 00 00 Front tyre pressure one-up ........2.5 bar (36.26 psi) two-up ........2.5 bar (36.26 psi) two-up with luggage....2.5 bar (36.26 psi) Rear tyre pressure one-up ........2.9 bar (42.06 psi) two-up ........2.9 bar (42.06 psi) two-up with luggage....

  • Page 35: Checking And Adjusting The Motorcycle

    Checking and adjusting the 00 00 motorcycle Checking the function of side 00 00 stand contact switch • Switch off the engine. • Place motorcycle on its centre stand. • Select a gear and switch on the ignition. – Temperature gauge warning light lights up. •...

  • Page 36: Installing The Seat

    Installing the seat Adjusting the handlebars, left/ 00 00 00 00 right Attention: When installing, make sure that the seat is retained Warning: firmly. Do not twist the handlebars, because this leads to air getting into the brake circuit or hydraulic circuit •...

  • Page 37: Adjusting Footrests Left/Right

    Adjusting footrests left/right Adjusting gearshift lever 00 00 00 00 Warning: If the motorcycle is to be ridden by a sporty rider, fit the footrests in the upper position. • Remove the left/right footrest support. • Install the left/right footrest support in the alter- native position.

  • Page 38: [Integral Abs] Performing Bleed Test With Bmw Moditec

    Brake light (operate front and rear brakes) Warning: – Turn signals left/right When performing maintenance and repair work on – Hazard warning flashers the BMW Integral ABS, avoid rapid and forceful – Horn pumping of the brakes. – Telltale and warning lights •...

  • Page 39: Handover

    How to adjust the mirrors – Controls – Instruments and telltale and warning lights – Procedure and noises of BMW Integral ABS self- diagnosis Note: Starting on gradients: Always switch on the ignition with gear engaged and both brake levers released. Self-diagnosis cannot be performed successfully if you do not follow this procedure.
  • Page 40 Pushing the motorcycle onto a workshop platform ( 00.21) ............35 Reading the BMW MoDiTeC fault code memory ............35 (Inspections I, II, III and IV) .........................35 [Integral ABS] Perform bleed test with BMW MoDiTeC .........35 (Inspections II and III) .........................35 Checking throttle cable play, adjusting if necessary ..........36 (Inspections I and III) .........................36...
  • Page 41 [Integral ABS] Filling brake-fluid reservoir for rear wheel circuit and rear control circuit ( 00.50) ....................56 [Integral ABS] Performing bleed test with BMW MoDiTeC ( 00.35) ....56 (Inspection IV) annual ........................56 [Option without Integral ABS] Checking brake fluid level front and rear ..57...
  • Page 42 Contents Page [Option without Integral ABS] Changing brake fluid and bleeding the brake system ..........................58 (Inspection IV) annual ........................58 Front brake ............................58 Force back the brake pistons......................58 Change and bleed the front brake circuit...................58 Bleeding the front left brake caliper ....................59 Bleeding the front right brake caliper ....................59 Rear brake ............................60...
  • Page 43 Checking swinging arm bearings, adjusting if necessary ........73 (Inspections I and III) .........................73 [Option without BMW Integral ABS] Cleaning inductive signal transmitter at rear wheel ..........................73 Clean the inductive sensor at the rear wheel every 40,000 km (24,000 miles) or every 2 years at the latest ............................73...

  • Page 44: Maintenance

    Reading the BMW MoDiTeC Maintenance intervals consist of the first Inspection 00 00 (after the first 1,000 km / 600 miles), the BMW Ser- fault code memory vice, BMW Inspection and BMW Annual Service. (Inspections I, II, III and IV) Inspection 1,000 km (600 miles) •...

  • Page 45: Checking Throttle Cable Play, Adjusting If Necessary

    Checking throttle cable play, 13 00 adjusting if necessary (Inspections I and III) • With the handlebars turned to various angles, open the throttle twistgrip fully and allow it to clo- se again. – When released, the twistgrip must return to the closed position by itself.

  • Page 46: [Cruise Control] Models With Cruise Control

    [Cruise control] Models with • 13 00 Back off adjusting screw (3) of the closer cable (4) until total play of the two cables (opener cruise control. and closer cables) is approx. 1...max. 1.5 mm (0.0394 in... max. 0.0591 in). •...

  • Page 47: [Cruise Control] Turning Throttle Twistgrip Relative To Throttle-Valve Shaft

    [Cruise control] Turning throttle 13 00 twistgrip relative to throttle-valve shaft Note: cruise-control system does not switch off • The throttle twist grip must be turned relative to the Increase opener cable play. • throttle-valve shaft if the switch for the cruise control Reduce play of the closer cable by the same on the throttle valve is not functioning correctly.

  • Page 48: Changing Engine Oil, Replacing Oil Filter Element

    • Drain the oil completely. • Remove the screws (2) holding the oil filter cover. • Unscrew the oil filter with special wrench (3), BMW No. 11 4 650. • Unscrew and remove the oil filter. BMW recommends Castrol 00.39...

  • Page 49: Gearbox Oil Change

    Gearbox oil change Rear wheel drive oil change 23 00 33 00 (every 40,000 km/24,000 miles) (Inspection III) (Inspections I and III) – Drain the oil from the gearbox only at regular – Drain the oil from the gearbox only at regular operating temperature.

  • Page 50: [Integral Abs] Checking Brake Pads/Brake Discs For Wear/Replacing If Necessary

    [Integral ABS] Checking brake [Integral ABS] Checking rear 34 00 34 00 pads/brake discs for wear/replacing brake pads for wear if necessary (Inspections II and III) [Integral ABS] Checking front 34 00 brake pads for wear K41000030 • Remove the cover from the brake caliper. •...

  • Page 51: [Integral Abs] Replacing Brake Pads

    • Fit new outer pad. Note: After switching on the ignition, always wait for the BMW Integral ABS to complete its self-diagnosis. Do not operate the brake lever until self-diagnosis has completed. • After replacing the pads of a caliper, bed in the new pads with the ignition switched on.

  • Page 52: Replacing Rear Brake Pads

    ............MIN Note: (top edge of the marking ring) After switching on the ignition, always wait for the BMW Integral ABS to complete its self-diagnosis. Brake fluid ...........DOT 4 Do not operate the brake lever until self-diagnosis has completed.

  • Page 53: [Integral Abs] Checking Operation Of Brake System And Freedom From Leaks; Repairing If Necessary

    Do not operate the brake lever until self-diagnosis has completed. Warning: When performing maintenance and repair work on the BMW Integral ABS, avoid rapid and forceful pumping of the brakes. • Apply the brake hard and hold on in this position for a short time.

  • Page 54: [Integral Abs] Changing Brake Fluid In Wheel Circuit/Bleeding

    Do not scrape the wheel – mask it off if necessary. • Use resetting tool, BMW No. 34 1 531, and loca- tor, BMW No. 34 1 532, to force the pistons in the left and right brake calipers all the way back and hold them in this position.

  • Page 55: Change The Front Brake Fluid/Bleeding

    Close the bleed screw. • • Slowly fill the filler bottle, BMW No. 34 1 581, to Release the brake and switch off the ignition. • approximately 1/2 its capacity with new brake Disconnect the brake bleeding device from the fluid.

  • Page 56: [Integral Abs] Reservoir Filling Instructions For Front Wheel Circuit

    00.42). 34 1 533 34 1 531 K41000090 • Screw the filler bottle, BMW No. 34 1 581, onto 34 1 532 the front wheel circuit reservoir. • Remove the adapter, BMW No. 34 1 533, and press back the pistons with the reset device until the brake pads can be inserted.

  • Page 57: [Integral Abs] Replacing Brake Fluid In The Rear Wheel Circuit/Bleeding

    • Remove cap (3) of rear wheel-circuit Attention: reservoir (4). Install piston resetting tool, BMW No. 34 1 531, • Draw off the old brake fluid from the wheel-circuit only when the cap has been removed from the reservoir (4).

  • Page 58: Change The Rear Brake Fluid/Bleeding

    Screw the filler bottle, BMW No. 34 1 581, onto BMW MoDiTeC! the rear wheel circuit reservoir. • • Slowly fill the filler bottle, BMW No. 34 1 581, to Perform bleed test with BMW MoDiTeC approximately 1/3 its capacity with new brake 00.35). fluid.

  • Page 59: Control Circuit

    BMW No. 34 1 531, in the brake caliper. • Install 23 adapter, BMW No. 34 1 534, in reset- • ting tool, BMW No. 34 1 531, in the brake cali- Perform bleed test with BMW MoDiTeC per. 00.35).

  • Page 60: [Integral Abs] Replacing Brake Fluid In The Control Circuit/Bleeding

    (Inspection IV) every 2 years Warning: When performing maintenance and repair work on Warning: the BMW Integral ABS, avoid rapid and forceful All repair and maintenance work on the pumping of the brakes. BMW Integral ABS should be carried out by •...

  • Page 61: [Integral Abs] Replacing Brake Fluid In The Front Control Circuit/Bleeding

    [Integral ABS] Replacing brake 34 00 fluid in the front control circuit/ Warning: When performing maintenance and repair work on bleeding the BMW Integral ABS, avoid rapid and forceful pumping of the brakes. • In sequence, bleed the: – Filler adapter (1), –...

  • Page 62: Bleeding The Control Circuit At The Filler Adapter

    When changing and bleeding the control circuit bra- • ke fluid, do not use vacuum extraction. Bleed system using the ring spanner, BMW No. 34 2 532, in accordance with • Tighten the bleed screw up to the stop in the filler instructions for bleeding.

  • Page 63: Front Control Circuit

    34 00 circuit to specified level 13 3 010 KR340850 • Remove special ring spanner, BMW No. 34 2 531 and silicon hose with hose K41000060 clip, BMW No. 13 3 010. • Screw in the battery tray. • Turn the handlebars to the left.

  • Page 64: [Integral Abs] Replacing Brake Fluid In The Rear Control Circuit/Bleeding

    Same procedure via other bleed screws as on front • control circuit, metering cylinder and integral Use special ring spanner BMW No. 34 2 532 circuits. and connect silicon hose with brake bleeding device to bleed screw (1), but do not switch on.

  • Page 65: Rear Integral Circuit

    Fit the protective caps on the bleed screws. KL000590 • Connect special ring spanner, BMW No. 34 2 532, and silicon hose with blee- ding unit to bleed screw (2), but do not switch • Bleed system using the ring spanner, BMW No.

  • Page 66: [Option Without Integral Abs] Checking Brake Fluid Level Front And Rear

    [Option without Integral ABS] Checking the rear brake fluid level 34 00 34 00 Checking brake fluid level front and rear Note: The volume of the brake fluid (MIN/MAX) is suf- (Inspections II and III) ficient for pad thicknesses from new to the wear li- mit.

  • Page 67: [Option Without Integral Abs] Changing Brake Fluid And Bleeding The Brake System

    Use resetting tool, BMW No. 34 1 531, and loca- During brake bleeding, make sure that the fluid rep- tor, BMW No. 34 1 532, to force the pistons in lenishing hole is always below the level of the brake the left and right brake calipers all the way back fluid, or else air will be drawn into the brake system.

  • Page 68: Bleeding The Front Left Brake Caliper

    Bleeding the front left brake caliper Bleeding the front right brake caliper • Connect the brake bleeding device to the bleed screw on the right brake caliper. • Open the bleed screw by half a turn. • Draw off brake fluid until it emerges clear and free from air bubbles.

  • Page 69: Rear Brake

    Dispose of old brake fluid in an environmentally-fri- endly manner. KR340820 Brake fluid ...........DOT 4 • Using resetting tool, BMW No. 34 1 531, force the pistons fully back. Tightening torque: Change and bleed the rear brake circuit. Bleed screw ..........10 Nm –...

  • Page 70: Checking Clutch Fluid Level, Correcting If Necessary

    Checking clutch fluid level, cor- 21 00 recting if necessary (Inspections II and III) Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint. – Place the motorcycle on its centre stand so that it is level.

  • Page 71: Changing The Clutch Fluid/Bleeding The Clutch System

    Changing the clutch fluid/blee- 21 00 ding the clutch system (Inspection IV) every 2 years – Place the motorcycle on its main (centre) stand. • Turn the handlebars to the right. Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint.

  • Page 72: Renewing Fuel Filter (Every 40,000 Km/24,000 Miles)

    16 1 710 K41160020 Renewing fuel filter Removing/installing fuel-pump 16 00 16 00 (every 40,000 km/24,000 miles) unit • Remove seal (6) and union nut (7). • (Inspection III) Pull fuel pump unit (5) far enough out of the fuel tank to enable the clips on drain hose (3) and breather hose (4) to be undone with pliers.

  • Page 73: Removing/Installing Fuel Filter

    Connect drain hose (3) and breather hose (4). Open fasteners (8) with pliers. • Close fasteners with pliers, BMW No. 13 1 500. Disconnect fuel hoses (12) and (9) from fuel • Install gasket (6) and union nut (7) and tighten.

  • Page 74: Removing/Installing Fuel Pump

    • Pull fuel pump (15) with pump inlet vibration Offer up the new intake filter and secure it with damper (17) off holder (19). pliers, BMW No. 13 1 500. • • Pull pump inlet vibration damper (17) off fuel Further installation is the reverse of the removal pump (15).

  • Page 75: Checking Coolant Level And Concentration; Topping Up If Necessary; Checking Cooling System For Leaks If Necessary

    KR170080 Checking coolant level and 17 00 concentration; topping up if neces- Attention: sary; checking cooling system for Anti-freeze protection must be guaranteed to at leaks if necessary least -30 °C (-22 °F). Use only nitrite-free long-term antifreeze and corrosion inhibitor. (Inspections I and III) Do not top up expansion tank over the MAX mark (arrow).

  • Page 76: Changing Coolant

    Changing coolant 17 00 Draining coolant 17 00 – Remove left side section of fairing, right rear sec- tion and engine spoiler ( 46.10). • Open the filler cap on the left radiator. KR170010 • Slacken fastener (2) for breather hose. •...

  • Page 77: Adding Coolant

    Adding coolant 17 00 • Install the expansion tank and tighten screw (1). Attention: Ensure that the breather hose is free of kinks and constrictions. • Connect coolant hose to oil/water pump. Positi- on the clip screw (arrow) at the front and tighten •...

  • Page 78: Checking Battery

    Checking battery 61 00 Attention: (Inspections III and IV) Reconnect the battery only when the ignition is swit- ched off. To avoid short-circuits: Check battery acid level and add distilled water Connect the positive battery lead (+) first, if necessary; inspect battery terminals and clean position the protective cap over the positive battery and grease them if necessary terminal,...

  • Page 79: Adding Distilled Water

    Replacing intake air filter ele- • Installation is the reverse of the removal proce- 13 00 dure. Pay particular attention to the following: ment (Inspection III) Note: If the motorcycle is used in very dusty or dirty con- ditions, replace the intake air filter every 10,000 km (6,000 miles) or even more frequently.

  • Page 80: Checking Function Of Side-Stand Switch

    46 5 710 KR460550 • Retract the centre stand. • Using spring tensioner, BMW No. 46 5 710, ten- sion the springs until they can be detached from KL000410 the pivot mount (arrow). • Release the spring tensioner and take off the pla- •...

  • Page 81: Checking The Steering Damper

    KR460270 Checking the steering damper 31 00 Attention: Mounting bolts (1) are secured with a thread-locking compound. Do not overheat the O-rings (3) when (Inspections II and III) softening the thread-locking compound. • Place the handlebars in full left-hand lock. •...

  • Page 82: Checking Tightness Of Rear Wheel Studs

    [Option without BMW Integral Checking tightness of rear 36 00 33 00 ABS] Cleaning inductive signal wheel studs transmitter at rear wheel (Inspection I) • Tighten the rear wheel studs with a torque wrench. Clean the inductive sensor at the rear wheel...

  • Page 83: Checking Valve Clearances, Adjusting If Necessary

    Prevent the chain tensioner from moving in the ti- Attention: ming case cover with chain tensioner pin, Never unscrew the spark plugs before measuring BMW No. 11 6 740. valve clearances. Particles of oily soot could beco- me lodged behind the exhaust valve head and falsify the measurement.
  • Page 84 When turning the crankshaft, make sure that the ti- • Take out the camshafts. ming chain does not come away from the crankshaft • Use a rubber extractor, BMW No. 11 3 251, to sprocket. withdraw the relevant bucket tappets from the • cylinder head.

  • Page 85: Replace The Lining Of The Chain Tensioning Rail, Chain Guide Rail And Thrust Piece

    • • Turn the engine over and check the relative po- Tighten all screws until sealed. • sitions of the camshaft chain sprockets and the Tighten the screws in diagonally opposite se- crankshaft (at TDC). quence, working from the inside outwards. •...

  • Page 86: Replacing Spark Plugs

    • • Unscrew and remove spark plugs (3) with spark Handbrake and foot brake, Integral ABS • plug wrench, BMW No. 12 3 500. Lights and signalling equipment • • Installation is the reverse of the removal proce- Telltale and warning lights •...
  • Page 87 11 Engine Contents Page Technical Data ..........................5 Preparatory work with engine installed ................. 11 …for removal of combined oil/water pump ................ 11 …for removal of timing case cover, removal of timing chain ........11 …for removal of cylinder head, removal of piston with conrod .........
  • Page 88 Contents Page Removing, disassembling and assembling cylinder head ..........19 Removing camshafts .........................19 Removing bucket-type tappets ......................19 Removing cylinder head ........................19 Removing valves ..........................19 Remachining valve seat ........................20 Installing valve and valve stem seal ....................20 Removing/installing coolant sealing cap at top of cylinder head ............21 Removing crankshaft ........................22 Removing big end bearings .......................22...
  • Page 89 Contents Page Assembling engine ........................36 Installing output shaft ........................36 Assembling the crankcase ........................36 Installing oil mesh strainer .........................37 Installing oil filter ..........................37 Installing oil sump ..........................37 Installing intermediate flange ....................38 Installing freewheel ..........................38 Installing countershaft ........................38 Installing intermediate flange ......................38 Installing output shaft sealing ring .....................38 Installing clutch housing ........................39 Installing driver ..........................39...
  • Page 90 Contents Page 11.4...

  • Page 91: Technical Data

    Technical Data K 1200 RS (72 kW) K 1200 RS (96 kW) Engine, general Engine design Inline four-stroke engine installed longitudinally, with double overhead camshafts and four valves per cylinder, liquid cooling and electronic fuel in- jection. Location of engine number...
  • Page 92 Technical Data K 1200 RS (72 kW) K 1200 RS (96 kW) Oil pump Oil pump Gear-type Valves Included angle between valves Inlet ° 20.5 Exhaust ° 19.5 Valve clearances with engine cold (max. 35 °C/95 °F) Inlet valve mm (in) 0.15…0.20 (0.0059...0.0079) Exhaust valve mm (in) 0.25…0.30 (0.0098...0.0118)
  • Page 93 Technical Data K 1200 RS (72 kW) K 1200 RS (96 kW) Valve seat Valve seat angle Inlet ° 45 Exhaust ° 45 Valve seat width Inlet mm (in) 0.95…1.25 (0.0374...0.0492) Wear limit mm (in) 2.5 (0.0984) Exhaust mm (in) 1.15…1.45 (0.0452...0.0570) Wear limit mm (in) 3.0 (0.1181)
  • Page 94 Technical Data K 1200 RS (72 kW) K 1200 RS (96 kW) Camshaft Inlet camshaft ° 284 Exhaust camshaft ° 284 Guide bearing dia. mm (in) 29.970…30.000 (1.1799...1.1811) Wear limit mm (in) 29.95 (1.1791) Guide bearing bore mm (in) 30.020…30.041 (1.1819...1.1827) Camshaft bearing bore mm (in) 24.020…24.041 (0.9457...0.9465)
  • Page 95 Technical Data K 1200 RS (72 kW) K 1200 RS (96 kW) Connecting rod Big end bearing with bearing shell Radial clearance mm (in) 0.030…0.066 (0.0012...0.0026) Wear limit mm (in) 0.130 (0.0051) Piston pin bore dia. with bushing mm (in) 17.000…17.021 (0.6693...0.6701) Distance between centers mm (in) 130.9…131.1 (5.1535...5.1614)
  • Page 96 Technical Data K 1200 RS (72 kW) K 1200 RS (96 kW) Piston rings 1st groove: square-section ring Height mm (in) 0.975…0.990 (0.0383...0.0389) Wear limit mm (in) 0.90 (0.0354) mm (in) 0.20…0.40 (0.0079...0.0157) Wear limit mm (in) 1.50 (0.0590) Float mm (in) 0.040…0.075 (0.0016...0.0030)

  • Page 97: Preparatory Work With Engine Installed

    Preparatory work with engine …for removal of crankshaft 1100 1100 installed – Remove the right side section of the fairing 46.8). …for removal of combined oil/ 1100 water pump …for removal of intermediate flange, removal of output shaft – Remove the right side section of the fairing 46.8).

  • Page 98: Removing/Installing Engine

    – Remove left/right radiators with fans ( 17.7). Connect cables and connectors for engine and • Secure lifter, BMW No. 00 1 510, to oil sump. gearbox, and secure them with cable ties. • – Remove exhaust system ( 18.5).

  • Page 99: Disassembling Engine

    Removing the oil/water pump Drive out slipring seal (7) and shaft sealing • Disconnect oil pressure warning and water pump ring (6) with a drift, BMW No. 11 6 721. temperature sensor cables from switch. • Withdraw cables through hole in pump housing.

  • Page 100: Removing The Oil Pressure Switch And Regulating Element

    Insert pump shaft (5) (lightly oiled) into the hous- ing. • • Remove greased sealing ring (14), regulating Place sliding sleeve, BMW No. 11 6 722, on element (13) and coil spring (12). pump shaft. • Insert shaft sealing ring (6) into the guide sleeve Installing oil pressure switch and regulating ele- of pressing-in tool, BMW No.

  • Page 101: Removing Timing Chain Cover

    KR110200 Removing timing chain cover 1100 Removing cylinder head cover Remove the crankcase cover. KL000010 • Remove heat shield (7). KR110210 • Pull off spark plug caps (6) with flat pliers. • Remove cylinder head cover (8). Removing ignition trigger Note: •...

  • Page 102: Removing Timing Case Cover

    Turn or press the camshaft in the normal direction of er with slip-over sleeve, BMW No. 11 6 771/772. rotation (for about 20 to 30 seconds if the engine is •...

  • Page 103: Removing/Installing Shaft Sealing Ring In Timing Case Cover

    BMW thinners. 11 6 771 KL110410 • Using assembly sleeve, BMW No. 11 6 772, slip the shaft sealing ring with wording as indicated (arrow) over assembly sleeve, BMW No. 11 6 771. •...

  • Page 104: Removing The Timing Chain

    KR110260 Removing the timing chain 1100 Removing chain tensioner rail • Remove the keeper and washer. • Take off tensioner rail (4). Important: Removing chain guide rail • Set the piston to the centre of the cylinder Remove keepers (1) and washers (2) from pivot (cylinder 1 approx.

  • Page 105: Removing, Disassembling And Assembling Cylinder Head

    Turn the camshafts until the tips of the cams are clear. KR110280 • Install support plate, BMW No. 11 1 749, for the valve spring clamping device at the rear of the cylinder head (not the timing end). 11 1 740 KR110270 •...

  • Page 106: Remachining Valve Seat

    Place a shrink-fit tube approx. 20 mm (0.7874 in) long, on the valve stem and heat it up. • Drive in valve stem seal (1) with the assembly tool, BMW No. 11 1 602, until resistance is felt. Important: Remove the shrink-fit sleeve from the valve stem. •...

  • Page 107: Removing/Installing Coolant Sealing Cap At Top Of Cylinder Head

    (2) until it is at a right angle in its bore. • Drive in coolant sealing caps (1) and (2) until seated below bevel, using hammer and drift, BMW No. 11 6 761. • Fill the cooling system. – Check cooling system for leaks ( 17.11).

  • Page 108: Removing Crankshaft

    Removing crankshaft 1100 Removing main bearings (engine installed) Note: Remove the driver first if the intermediate flange is also to be removed after the crankshaft. Removing big end bearings • Bring pistons 1 and 4 to BDC position. KR110330 • Loosen all but one (arrow) of the main bearing bolts.

  • Page 109: Removing, Disassembling And Assembling Piston With Conrod

    • Remove the circlip (3) at one side. • Press out piston pin (2) with pressing-out tool, KR110360 BMW No. 11 6 710. • Carefully remove piston rings (1) with piston-ring • pliers. Measure piston diameter with a micrometer at distance “A”.

  • Page 110: Assembling Pistons

    Assembling pistons Checking that conrod bores are parallel 0,06 KR110371 KR110400 • • Install piston rings, using piston-ring pliers. The difference over the reference length “P” must not exceed 0.06 mm (0.0024 in). Note: Reference length “P” ....150 mm (5.9055 in) The “Top”...

  • Page 111: Assembling Pistons And Conrods

    • Assembling pistons and conrods Only install pistons of the same weight group. Important: It should be possible to push the piston pin through the small end bushing with only slight pressure. • Note weight tolerances when replacing conrods: use only conrods of the same weight class. Weight tolerance ......

  • Page 112: Removing/Installing Crankshaft Gear And Rotor Flange

    – Remove alternator ( 12.10). • Secure dial-guage holder, BMW No. 00 2 500, to gearbox intermediate flange. • Use the clamping screw to secure the clamp, BMW No. 11 5 510, to the first vane of the driver. 11.26...

  • Page 113: Removing Intermediate Flange

    KL110231 • Pull the driver off by hand. • If necessary, use a puller, BMW No. 00 8 400, • Install the retaining device (arrow), with the pressure head from puller-separator, BMW No. 11 2 821, in the position illustrated.

  • Page 114: Removing Intermediate Flange

    KR110090 Removing clutch housing Removing intermediate flange • Use Torx socket T30, BMW No. 00 2 600, to re- lease the screws. • Important: Remove the intermediate flange. After unscrewing nut (1), do not strike the output shaft or turn the engine over, so that output shaft endplay cannot cause damage to the crankcase or pump housing.

  • Page 115: Disassembling/Assembling Intermediate Flange

    Remove thrust plate (1). • Take off cup spring (2). • Remove ball bearing (3) with puller, BMW No. 00 8 570, and internal puller 21/3, BMW No. 00 8 574. • Remove snap ring (4). Installing driver bearing •...

  • Page 116: Removing/Installing Shaft Sealing Ring For Driver

    BMW No. 00 7 500. Note: Clean the sealing ring seat. • Pre-shape the sealing ring with your thumbs and drive it in dry with a drift, BMW No. 11 1 620, and handle, BMW No. 00 5 500. 11.30...

  • Page 117: Disassembling/Assembling Freewheel

    • Pull off freewheel cage (3). • Take out cup spring (2). KR110170 • Pull needle roller bearing out of freewheel gear with a puller, BMW No. 00 8 570, and internal puller 21/3, BMW No. 00 8 574. 11.31...

  • Page 118: Assembling Freewheel

    (x) is the same at both sides. • Place support ring, BMW No. 11 6 731, in posi- Distance “X” ..0.2…0.6 mm (0.0079...0.0236 in) tion and remove bearing with puller, BMW No. 00 8 570, and internal puller 21/3, •...

  • Page 119: Removing Output Shaft

    Coat the sealing face of the new oil level sight glass with tyre assembly paste and drive it in with Removing the oil mesh strainer and oil filter drift, BMW No. 00 5 550. • Take out the screw and pull off oil mesh strainer (1).

  • Page 120: Disassembling/Assembling Output Shaft

    Disassembling/assembling output • 1100 Remove retaining ring (4) with suitable pliers. • Insert a puller, BMW No. 00 8 400, in the oppo- shaft site cutout of the gearwheel and pull ball Disassembling output shaft bearing (5) off with pressure block, •...

  • Page 121: Assembling Tensioning Gear

    • Attach the tensioning spring to the pin in the ten- sioning gear and turn it clockwise with the coun- ter-holder, BMW No. 12 4 600 until the pin of the tensioning gear engages the hole in the gear. •...

  • Page 122: Installing Dampers

    KR110451 Installing dampers Assembling the crankcase • Insert the rubber dampers (7) into the damper housing (6). Note: New parts must be oiled lightly. • Push the retaining plate (4) onto the output shaft (3), slightly heat the inner part of the damper (5) and press it into position on the shaft.

  • Page 123: Installing Oil Mesh Strainer

    Tighten oil filter (2) with the special oil filter Check that sealing face is clean and degreased wrench, BMW No. 11 4 650, by not more that and apply a thin coat of Omni VISC 1002, see half a turn once it has made contact.

  • Page 124: Installing Intermediate Flange

    (arrow) projects upwards and is pre-loaded against Install the intermediate flange (with locating the freewheel gear. sleeves). • Use Torx socket T 30, BMW No. 00 2 600, to • Insert the countershaft into the crankcase with tighten the screws. the small gearwheel facing down.

  • Page 125: Installing Driver

    • Slacken and then retighten the nut (50 Nm). • Use angle-of-rotation gauge, BMW No. 11 2 500, to tighten the nut fully. Tightening torque: 1. Nut for clutch housing ......140 Nm 2. Slacken off ............3. Retighten ..........50 Nm 4.

  • Page 126: Measuring Crankshaft Bearing Play

    • Remove bearing cap. • Screw dial gauge holder (arrow), BMW No. 00 2 500, with dial gauge attached into the tapped hole for the timing case cover. • Move the crankshaft backwards and forwards as far as it will go and take the dial gauge readings.

  • Page 127: Installing Piston With Conrod

    Use an angle-of-rotation gauge, • Carefully push the piston by hand out of the BMW No. 11 2 500, to tighten the big end bear- sleeve and into the cylinder. ings. Installing big end bearings...

  • Page 128: Checking Dimensions Of Crankshaft

    • Use an angle-of-rotation gauge, BMW No. 11 2 500, to tighten the big end bearings. Tightening torque: Conrod bearings .......... 20 Nm Additional angle of rotation........ 80°...

  • Page 129: Installing Cylinder Head

    Set the piston in cylinder 1 to approx. 90° before Install angle-of-rotation gauge, top dead centre BMW No. 11 2 500, with two Torx inserts T 50, (cylinder 1 = at timing end of engine). BMW No. 00 2 630.

  • Page 130: Installing Camshafts

    KL110120 • Important: Place aligning device, BMW No. 11 3 700 in po- Set the piston to the centre of the cylinder sition and secure it to the camshaft bearing (cylinder 1 approx. 90° before top dead centre), to caps.
  • Page 131 Install the snap rings (1) and washers (2) for the Tighten the bearing cap with sliding rail (7). • guide rail on the two bearing journals. Remove the aligning device, BMW No. 11 3 700. • Tighten the chain sprockets, counter-holding at hexagon of the camshaft.

  • Page 132: Installing Timing Case Cover

    • • Install chain tensioner in timing case cover. Use assembly sleeve, BMW No. 11 6 771, to po- • Prevent chain tensioner from moving with pin, sition the timing case cover on the rotor flange BMW No. 11 6 740.

  • Page 133: Installing Ignition Trigger

    KR110710 Installing ignition trigger 1100 Installing ignition trigger cover • Run the cable to the ignition trigger through a • Install adjusting disc and rotor on crankshaft, rubber grommet in the timing case cover. • and tighten. Secure the cables for the oil pressure telltale and •...

  • Page 134: Installing Combined Oil/Water Pump

    Installing combined oil/water 1100 pump Note: Turn the crankshaft to centre the gearwheels, tight- ening the screws further at the same time. Important: • Tighten the clutch housing before installing the oil/ Tighten the screws to specified torque. • water pump, so that the output shaft cannot dam- Check for any noticeable play at any position of age the pump housing.

  • Page 135: Installing Cylinder Head Cover

    Installing cylinder head cover • 1100 Screw in all bolts until sealed. • Tighten the bolts in diagonally opposite se- • Install spark plugs and ignition leads ( 12.7). quence, working from the inside outwards. • Mount the heat shield on the cylinder head co- ver.

  • Page 136: Engine Electrics

    12 Engine electrics Contents Page Technical Data ..........................3 Renewing Hall-effect transmitter ..................5 Removing cover from Hall-effect transmitter ...............5 Removing magnetic gate ......................5 Installing the magnetic gate .......................6 Installing the cover of the Hall-effect transmitter ...............6 Replacing spark plugs/ignition leads ................7 Removing/installing spark plugs ....................7 Removing/installing ignition leads...
  • Page 137 Contents Page 12.2...

  • Page 138: Technical Data

    Technical Data K 1200 RS Starter motor Type Permanent-magnet motor Gear ratio 27:1 Power rating kW 0,7 Alternator Type Three-phase AC generator Gear ratio 1:1.5 Drive direct Maximum output rating W/V 840/14 Maximum current A 60 Three-phase generator speed for start of charge rpm 1,400 Max.
  • Page 139 12.4...

  • Page 140: Renewing Hall-Effect Transmitter

    KR110200 Renewing Hall-effect transmitter 12 11 – Remove the right side section of the fairing 46.10). – Remove the engine spoiler ( 46.14). – Drain coolant ( 00.67). – Disconnect the right-hand coolant hose. Removing cover from Hall-effect 12 11 transmitter •...

  • Page 141: Installing The Magnetic Gate

    KR110200 Installing the magnetic gate Installing the cover of the Hall- 12 11 12 11 effect transmitter • Place adjusting disc (3) and rotor (2) on crank- shaft, and tighten. • Install magnetic gate (1) in the same position as previously marked.

  • Page 142: Replacing Spark Plugs/Ignition Leads

    Pull off spark plug caps (2) with flat pliers. Removing/installing spark plugs 12 12 • Unscrew and remove spark plugs (1) with spark plug wrench, BMW No. 12 3 500. • Installation is the reverse of the removal proce- dure. Tightening torque: Spark plugs..........

  • Page 143: Timing The Ignition

    Ignition firing point..6° before TDC = 0.24 mm Loosen the fasteners of magnetic gate (1) and ........... (0.0094 in) before TDC turn it to the left or right until the BMW MoDiTeC displays the correct ignition firing point. •...

  • Page 144: Removing/Installing Coil

    KR120110 Removing/installing coil 12 13 Important: Note positions of ignition leads on coil. Important: Switch off the ignition and disconnect and insulate the earth (ground) lead at the battery. – Remove left side section of fairing ( 46.10) • Disconnect the ignition lead plugs (6) from the coil.

  • Page 145: Replacing Three-Phase Generator

    Replacing three-phase generator 12 31 Removing three-phase generator 12 31 Note: Important: For further information on the work described below, Unscrew the three fasteners uniformly and in diago- see brief version of instructions ( 46.29) or full de- nally opposite sequence. scription in the relevant chapters.

  • Page 146: Disassembling The Three-Phase Generator

    Unlock the clips (1) and take off the housing cover (2). 12 4 600 KR120120 • Hold drive housing (3) with retaining device, BMW No. 12 4 600, to prevent it from turning, KR120140 release fastener (2) and take it off together with the spring washer. • •...

  • Page 147: Installing Generator

    Installing generator 12 31 – Install the left/right radiators with fans ( 17.7). – Install the lower cross-tube ( 46.25). – Install drive shaft and swinging arm ( 33.21). – Install the rear wheel drive ( 33.19). – Remove lifter from engine sump. –...

  • Page 148: Replacing Starter Motor

    Replacing starter motor 12 41 Removing starter motor 12 41 Note: Important: For further information on the work described below, Unscrew the three fasteners uniformly and in diago- see brief version of instructions ( 46.29) or full de- nally opposite sequence. scription in the relevant chapters.

  • Page 149: Disassembling And Reassembling Starter Motor

    12 11 KR120090 Disassembling and reassembling 12 41 Removing/installing brush holder • Unscrew hex nut (6). starter motor • Take off outer insulating washer (5). • • Clamp the starter motor in the vise (with soft Take off brush holder plate (3) with carbon brush jaws) at its retaining lugs.

  • Page 150: Installing Starter Motor

    Installing starter motor 12 41 – Install the left/right radiators with fans ( 17.7). – Reconnect plugs and cables for engine and gearbox. – Install the lower cross-tube ( 46.25). – Install drive shaft and swinging arm ( 33.21). – Install the rear wheel drive ( 33.19).

  • Page 151: Fuel Preparation And Control

    13 Fuel preparation and control Contents Page Technical Data ..........................3 Removing/installing Motronic control unit ..............5 Removing/installing intake air filter ( 00.70) ...............5 Replacing air temperature sensor ..................5 Removing/installing intake air silencer ................6 Removing/installing fuel injection rail ................7 Removing/installing injectors ....................8 Removing/installing pressure regulator ................8 Removing/installing throttle-valve rail...
  • Page 152 Contents Page 13.2...

  • Page 153: Technical Data

    Technical Data K 1200 RS Fuel grade Super (premium), unleaded, 95 octane (RON) Mixture preparation Motronic MA 2.4 Fuel pressure bar (psi) 3.5 (50.76) Throttle stub pipe intl. dia. mm (in) 38 (1.4960) Air filter Multi-layer paper element Intake stub pipe...
  • Page 154 13.4...

  • Page 155: Removing/Installing Motronic Control Unit

    Removing/installing Motronic Replacing air temperature sen- 13 61 13 62 control unit • Take off the left side section of the fairing Warning: 46.10). Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressu- rised.

  • Page 156: Removing/Installing Intake Air Silencer

    Pay particular attention to the following: • Secure non-reusable hose clips (2, 3) with pliers, KR170130 BMW No. 13 1 510. • Make sure that screw of hose clamp (4) on cylin- • Remove the fasteners (arrows). Take off the radi- der No.

  • Page 157: Removing/Installing Fuel Injection Rail

    Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressu- rised. • Use hose clamps, BMW No. 13 3 010, to close off fuel hoses (3). • Release hose clips of fuel hoses (3). Pull off the fuel hoses.

  • Page 158: Removing/Installing Injectors

    Take off the left side section of the fairing It is not necessary to open the cable ties (1). 46.10). • Use hose clamps, BMW No. 13 3 010, to close • Remove fuel injection rail. off fuel hoses at injection rail.

  • Page 159: Removing/Installing Throttle-Valve Rail

    Removing/installing throttle- 13 54 valve rail – Take off the right side section of the fairing 46.10). KR170140 • Disconnect the plug (arrow) for the fan. Note: It is not necessary to open the cable ties when re- KR130260 moving the fuel injection rail. •...

  • Page 160: Removing/Installing Intake Stubs

    Removing/installing intake 11 61 stubs • Remove throttle-valve rail. KL130030 • [Cruise control] Remove retainer (8). • [Cruise control] Disengage throttle-closer cable (5) from its pull at the throttle-valve rail and remove throttle-closer cable (5). KR130090 • [Cruise control] Disengage Bowden cable for cruise control.

  • Page 161: Replacing Fuel Hoses

    Replacing fuel hoses 13 31 • Remove throttle-valve rail. KR130270 Important: KR130100 Make sure that the fuel hoses and protective sleeves are run correctly between the frame and the • Open the retaining clip (arrow). engine. • Insert the fuel hoses in the retaining clips. Note: Renew retaining clips if necessary.

  • Page 162: Removing/Installing Throttle-Valve Actuator

    BMW MoDiTeC. • Mark the screw with paint. • • Remove the fasteners (arrows). Perform function test with BMW MoDiTeC, menu • Remove the throttle-valve actuator. item THROTTLE-VALVE POTENTIOMETER or throttle-valve actuator. Important: The throttle-valve actuator operates from the 5 volt Tightening torque: control-unit supply.

  • Page 163: Basic Throttle Cable Setting ( A 00.36)

    Install the new throttle-valve potentiometer. Note: throttle-valve actuator must be installed and con- nected. Throttle-valve potentiometer must be con- nected. • Connect BMW MoDiTeC to diagnosis plug be- neath front seat. • Open the TOOLBOX menu and select THROT- TLE-VALVE POTENTIOMETER or throttle-valve actuator.

  • Page 164: [Cruise Control] Removing/Installing Throttle Cables

    [Cruise control] Removing/ Removing/installing throttle- 32 73 32 72 installing throttle cables opener and throttle-closer cables Preparatory work for all Bowden cables – Remove left side panels ( 46.8). Warning: Comply with safety precautions when handling or working with fuel. –...
  • Page 165 K41130010 • Installation is the reverse of the removal proce- dure. Pay particular attention to the following: Important: Route Bowden cables so as to avoid tight bends and make sure they are not kinked or pinched. • Route the two cables parallel; the throttle-opener cable (1) with green mark always to the outside.

  • Page 166: Removing/Installing Bowden Cable Of Cruise-Control System

    K41130010 Removing/installing Bowden • 32 73 Installation is the reverse of the removal proce- dure. Pay particular attention to the following: cable of cruise-control system • Carefully pull apart sleeve (4) and lower cable shroud (arrow) and remove insert (3). Important: •...

  • Page 167: [Cruise Control] Removing/Installing Control Unit For Cruise Control

    [Cruise control] Removing/ 65 71 installing control unit for cruise con- trol – Remove left side section of fairing ( 46.8). – Remove upper section of fairing ( 46.9). K41130030 • Disconnect plug (arrow). • Remove screws (4) securing retaining plate to fairing bracket.

  • Page 168: Checking Fuel Pressure

    Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressu- rised. • Connect a test pressure gauge, BMW No. 16 1 500, to the delivery side (lower line). • Start engine and allow to idle. Fuel pressure: Specification ......

  • Page 169: Troubleshooting

    Troubleshooting Fault indication from BMW MoDiTeC: Leak in air intake line. Injector leaking? Renew injector/sealing ring. Intake air stub leaking? Renew intake air stub. 13.19...
  • Page 170 16 Fuel tank and lines Contents Page Technical Data ..........................3 Removing/installing fuel tank ....................5 Removing/installing fuel pump assembly, fuel filter and fuel pump ....6 Removing/installing fuel-pump unit ( 00.63) ..............6 Removing/installing fuel filter ( 00.64) .................7 Removing/installing fuel pump ....................7 Removing/installing fuel filler pipe ..................7 Removing/installing fuel tank vent...
  • Page 171 Contents Page 16.2...

  • Page 172: Technical Data

    Technical Data K 1200 RS Tank capacity 21 (4.62/5.55) (Imp. gal /US gal) including reserve of 4 (0.88/1.06) (Imp. gal /US gal) Fuel pump Type Gear-type Operating voltage V 12 Delivery volume 110 (24.21/29.06) (Imp. gal/ US gal/h) 16.3...
  • Page 173 16.4...

  • Page 174: Removing/Installing Fuel Tank

    K41160010 Removing/installing fuel tank • 16 11 Disconnect the plug for the immersed fuel level sensor (5). • Release the fasteners (4) at the left and right of Note: the fuel tank. Pull the fuel tank to the rear, away The immersion-tube sensor has to be calibrated if it from rubber mounting (7).

  • Page 175: Removing/Installing Fuel-Pump Unit

    16 1 710 K41160020 Removing/installing fuel pump Removing/installing fuel-pump 16 11 16 14 assembly, fuel filter and fuel pump unit ( 00.63) • Remove fuel tank. Warning: Comply with safety precautions when handling or working with fuel. • Drain fuel tank. 16.6...

  • Page 176: Removing/Installing Fuel Filter ( A 00.64)

    Removing/installing fuel filter Removing/installing fuel filler 16 12 16 11 00.64) pipe Removing/installing fuel pump 16 12 Warning: Comply with safety precautions when handling or • Disconnect connecting cable (10) from fuel working with fuel. pump. • Open hose clip (11) with pliers and pull off the hose.

  • Page 177: Removing/Installing Immersion-Tube Sensor

    Removing/installing immersion- Renewing front left/right rubber 16 14 16 11 tube sensor mounting – Remove the right side section of the fairing 46.8). Important: Disconnect ground lead from battery and insulate. Warning: Comply with safety precautions when handling or working with fuel. KR160050 •...
  • Page 178 17 Radiator Contents Page Technical Data ..........................3 Coolant circuit ..........................5 Removing/installing radiator with fan ................7 Removing/installing left radiator ....................7 Removing/installing right radiator ....................8 Removing/installing fan ......................9 Removing/installing left fan ......................9 Removing the right fan ........................9 Removing/installing coolant hoses ..................10 Removing/installing thermostat ..................
  • Page 179 Contents Page 17.2...

  • Page 180: Technical Data

    Technical Data K 1200 RS Cooling system content (Imp. pint/ US quart) Coolant Use only nitrite-free long-term antifreeze and cor- rosion inhibitor. Thermostat opening temperature °C (°F) 85 Fan cut-in temperature °C (°F) 105 Cut-in temperature for coolant warning °C (°F) 115...
  • Page 181 17.4...

  • Page 182: Coolant Circuit

    Coolant circuit 17.5...
  • Page 183 17.6...

  • Page 184: Removing/Installing Radiator With Fan

    Removing/installing radiator 17 11 with fan Removing/installing left radiator 17 11 – Drain coolant ( 00.67). KR170130 • Release the retaining screws (arrows). Take off the radiator air outlet guide. KR170030 • Remove the fasteners (arrows). Take off the radi- ator air inlet guide.

  • Page 185: Removing/Installing Right Radiator

    Note: Illustrations for the following work: b Remove left radiator. • Remove retaining clips with washers for radiator. • Loosen air outlet guide mountings. Take off air outlet guide. • Disconnect fan plug. KR170040 • Disconnect connecting hose (1) to right radiator, vapour discharge hose (2) and breather hose (3) at the top of the radiator.

  • Page 186: Removing/Installing Fan

    Removing/installing fan Removing the right fan 17 11 17 11 Removing/installing left fan – Remove the right side section of the fairing 17 11 46.10). – Take off the left side section of the fairing 46.10) KR170050 KR170030 • Remove the fasteners (arrows). •...

  • Page 187: Removing/Installing Coolant Hoses

    KR170080 Removing/installing coolant • 17 12 Installation is the reverse of the removal proce- dure. hoses – Drain coolant ( 00.67). Tightening torque: • Remove the corresponding coolant hose. Hose clips for coolant hose.....hand-tight – Connecting hose (1) between left and right radi- ators –...

  • Page 188: Removing/Installing Thermostat

    • Screw pump, BMW No. 17 0 500, with adapter Checking thermostat 17 00 and threaded stub pipe, BMW No. 17 5 520, on to the filler pipe. • See “Troubleshooting” on Page 17.12 Pressure-test the cooling system; the pressure must remain unchanged for at least 5 minutes.

  • Page 189: Troubleshooting

    Troubleshooting Coolant overheat warning light comes on. Check coolant in expansion tank. Is coolant Add coolant. level too low? Check thermostat. Thermostat does not open. Is the left radiator warmer than the right, and Replace thermostat. the coolant pipe to the water pump hot? Test the water pump.
  • Page 190 Excessive loss of coolant. Check coolant circuit. Coolant circuit is inter- Repair the fault. rupted Engine remains cold or warms up very slowly. Check thermostat. Thermostat does not close. Are both radiators equally warm and the cool- Replace thermostat. ant hose to the water pump cold? 17.13...

  • Page 191: Exhaust System

    18 Exhaust system Contents Page Technical Data ..........................3 Removing/installing exhaust system .................5 Removing/installing oxygen sensor ..................5 Removing/installing exhaust system sleeve ..............6 18.1...
  • Page 192 Contents Page 18.2...
  • Page 193 Technical Data K 1200 RS Exhaust system Silencer (muffler) Closed-loop catalytic converter 18.3...
  • Page 194 18.4...
  • Page 195 Before installing, lightly oil the thread of the oxygen sensor. • Coat the oxygen sensor with Optimoly TA and tighten by means of hex head using socket, BMW No. 11 7 020. Tightening torque: Oxygen sensor ..........45 Nm 18.5...
  • Page 196 Removing/installing exhaust 18 30 system sleeve KR180050 KR180070 • • Remove fasteners (arrows) for cover. Pull the exhaust system sleeve away from the si- lencer with a turning movement (arrows). Note: When installing, push the sleeve on to the silencer with a turning movement, making sure that the holes in the sleeve and the silencer are aligned.
  • Page 197 21 Clutch Contents Page Technical Data ..........................3 Removing/installing clutch .....................5 Removing clutch ..........................5 Removing clutch housing ......................6 Installing clutch housing ......................7 Installing clutch ..........................8 Removing/installing clutch slave cylinder and pushrod ..........9 Removing/installing clutch slave cylinder ....................9 Removing/installing clutch pushrod ....................10 Removing/installing clutch lines ..................
  • Page 198 Contents Page 21.2...

  • Page 199: Technical Data

    Technical Data K 1200 RS Clutch Type Single dry plate clutch (asbestos-free) Operation hydraulic Clutch plate dia. mm (in) 180 (7.0866) Wear limit: Minimum clutch plate thickness mm (in) 4.5 (0.1771) 21.3...
  • Page 200 21.4...

  • Page 201: Removing/Installing Clutch

    (6) from the clutch housing (8). – Remove rear wheel ( 36.8). – [Without BMW Integral ABS] Remove inductive signal transmitter ( 61.15). – Remove brake caliper, fasten to the rear frame with the inductive sensor using a cable tie 34.5).

  • Page 202: Removing Clutch Housing

    Move clutch housing (2) to and fro until O-ring (3) can be seen. • Cut through O-ring (3). • Pull off the clutch housing (2). • Take off thrust washer (1). 11 2 821 KR210030 • Attach the holder, BMW No. 11 2 821, as illus- trated. 21.6...

  • Page 203: Installing Clutch Housing

    • Fit the clutch housing (2). Slacken and then retighten the nut. • Use angle-of-rotation gauge, BMW No. 11 2 500, to tighten the nut fully. • Remove the retaining fixture, BMW No. 11 2 821. Tightening torque: 1. Nut for clutch housing ......140 Nm 11 2 821 2.

  • Page 204: Installing Clutch

    KR210010 Installing clutch 21 21 Important: Offset colour markings for residual imbalance by Important: 120°: yellow on clutch housing (8), white on thrust Always use new screws. plate (4) and clutch housing cover (2). • • Grease all lubrication points with Install wire ring (6), diaphragm spring (5), thrust Optimoly MP 3.

  • Page 205: Removing/Installing Clutch Slave Cylinder And Pushrod

    – Remove swinging arm ( 33.21). • Centre clutch plate (3) with centering pin, BMW No. 21 2 673. • Tighten retaining screws (1) in succession, in di- agonally opposite sequence. Lubrication points: Splines on clutch plate and input shaft.

  • Page 206: Removing/Installing Clutch Pushrod

    • Installation is the reverse of the removal proce- 21 52 Removing/installing clutch pushrod dure. Pay particular attention to the following: KR210050 KL210080 • Clean mating surfaces on the transmission case Note: and clutch slave cylinder, use new paper Pressure line (3) and bleed line (5) remain on the gasket (arrow).

  • Page 207: Removing/Installing Clutch Lines

    KR210070 Removing/installing clutch lines 21 52 – Fill clutch system with brake fluid ( 00.62). – Bleed/adjust the clutch ( 00.62). – Install left side section of fairing ( 46.10). 21 52 Removing/installing clutch pressure line – Install the front section of the rear carrier –...

  • Page 208: Removing/Installing Bleed Line

    KR210080 21 52 Removing/installing bleed line – Remove the front section of the rear carrier 46.7). • Cut through cable tie (1) at frame. • Remove banjo bolt (4), take off sealing rings (3), trap brake fluid in a suitable container and dis- pose of it in an environmentally acceptable man- ner.
  • Page 209 23 Gearbox Contents Page Technical Data ..........................3 Gearbox - cutaway drawing ....................5 Replacing the shaft sealing rings in the gearbox housing and gearbox cover ........................7 Replacing input shaft sealing ring at input end ..................7 Replacing output shaft sealing ring .....................7 Replacing input shaft sealing ring at output side .................8 Replacing shaft sealing ring for selector drum ..................8 Replacing sealing ring for selector shaft ....................8...
  • Page 210 Contents Page Installing gearbox housing ......................26 Aligning rubber mounts ......................28 Aligning left-hand rubber mount ....................28 Aligning right-hand rubber mount ..................29 23.2...

  • Page 211: Technical Data

    Technical Data K 1200 RS Type of gearbox 6-speed with sports ratios, claw shift and inte- grated shock damper acting in all gears Gearshift type Adjustable shift pedal, selector drum with overrun protection Gear ratios 1st gear 3.863 2nd gear 3.022 3rd gear 2.393...
  • Page 212 23.4...

  • Page 213: Gearbox - Cutaway Drawing

    Gearbox - cutaway drawing KR230000 23.5...
  • Page 214 23.6...

  • Page 215: Replacing The Shaft Sealing Rings In The Gearbox Housing And Gearbox Cover

    All shaft sealing rings can be replaced with the gear- • box installed, apart from the input-side shaft sealing Screw puller, BMW No. 00 8 750, into shaft seal- ring on the input shaft. Replace all shaft sealing ing ring and turn the hex bolt to remove the shaft rings if the gearbox is fully disassembled.

  • Page 216: Replacing Input Shaft Sealing Ring At Output Side

    BMW No. 00 8 583. Install the new sealing ring with the sealing lip • Screw the pull rod, BMW No. 00 8 581, into the facing inwards, using assembly sleeve, pierced hole and use impact weight, BMW No. 23 4 612, and impact driver, BMW No.

  • Page 217: Removing/Installing Gearbox

    KR230010 Removing/installing gearbox • 23 00 Cut through the cable tie (arrow) and disconnect the cable for the side stand switch. Removing gearbox • Remove clutch release rod (3) from the gearbox. 23 00 • Undo fasteners (4, 5) and remove the heat shield. •...
  • Page 218 KR230010 Installing gearbox 23 00 Important: • Insert gearbox into intermediate flange and push The alignment of the left-hand rubber mounts rela- on to reamed sleeves. tive to the frame is preset at the factory; do not slacken the securing screws. The rubber mounts do not have to be re-aligned un- Note: less the left-hand rubber mount has been replaced.

  • Page 219: Disassembling Gearbox

    Avoid damage to the housing cover and painted sur- faces. • Heat the bearing seats in the housing to 80 °C... 100 °C/176 °F...212 °F). • Use press-off tool, BMW No. 23 4 780, to sepa- rate the housing from the housing cover. 23.11...

  • Page 220: Removing Selector Drum

    KR230040 Removing selector drum Disassembling/assembling selec- 23 31 23 31 tor shaft • Pull selector rails (1) out of selector forks. • Swing selector forks (2, 8, 9) out towards the edge of the cover. • Remove locking pin (5). •...

  • Page 221: Removing Gearbox Shafts

    If the grooved ball bearings are replaced, the fully Pull off the grooved ball bearings with a universal assembled length must be re-adjusted. puller, BMW No. 00 7 500. • Press the output-side grooved ball bearing on to the intermediate shaft.

  • Page 222: Disassembling/Assembling Input Shaft

    (3), thrust piece (2) and con- stant-speed gear (1). • Clamp input shaft (10) other way round in vise. • Use universal puller, BMW No. 00 7 500, and 00 7 500 pressure head (arrow) to pull off grooved ball bearing (11). KR230090 •...

  • Page 223: Assembling Input Shaft

    KR230080 • 23 12 Assembling input shaft Check the fully-compressed length and adjust if • Lightly oil the bearing surface for constant-speed necessary ( 23.22). • gear (1) on input shaft (10), and install the con- Install spacing washer (8) of the calculated thick- stant-speed gear.

  • Page 224: Disassembling/Assembling Output Shaft

    • Turn output shaft (6) other way round and clamp into the vise with soft jaws. • Use universal puller, BMW No. 00 7 500, to pull off grooved ball bearing (1). 00 7 500 • Remove shim washer (2), needle roller bearing (3), shift gearwheel for 2nd gear (4) and thrust washer (5).
  • Page 225 18 17 KR230120 23 12 Assembling output shaft Important: To avoid damaging the needle roller bearings on the Note: splines when installing, spread the rollers carefully Assembly starts at the shift at the end faces. gearwheel for 4th gear (9). Before assembly, oil all •...
  • Page 226 18 17 KR230120 KR230140 • Reverse position of output shaft (16) in vise. • Install sliding gearwheel for 6th gear (17) with the recess for the selector fork facing the 2nd gear shift wheel (20). • Install backup washer (18) and needle roller bearing (19).

  • Page 227: Checking Endplay

    KR230150 Checking endplay 23 00 KR230190 • Secure dial gauge, BMW No. 00 2 510, to dial • gauge stand. Place spacing washer and both thrust washers • Position dial-gauge stylus on edge of the gear- on the selector drum.

  • Page 228: Checking/Adjusting Fully-Assembled Length Of Gearbox Shafts

    Remove the spacing washer. ness on the intermediate shaft and press on the • Position dial gauge, BMW No. 23 4 762, in rear grooved ball bearing. locating bore of stand, BMW No. 23 4 761, and set to 0.2 mm (0.0079 in) preload.

  • Page 229: Checking/Adjusting Fully-Assembled Length Of Output Shaft

    • Remove the spacing washer. Take off spacing washer, grooved ball bearing • Position dial gauge, BMW No. 23 4 762, in rear and reference washer. • locating bore of stand, BMW No. 23 4 761, and Place a spacing washer (1) of the correct thick- set to 0.2 mm (0.0079 in) preload.
  • Page 230 Take the input shaft out of the measuring fixture. • • Position dial gauge, BMW No. 23 4 762, in front Remove the adapter disc, spacing washer, locating bore of stand, BMW No. 23 4 761, and grooved ball bearing and reference washer.

  • Page 231: Assembling Gearbox

    • Align the input, output and intermediate shafts so that their gearwheels mesh. • Insert slip-over sleeve for input shaft, BMW No. 23 4 712, into cover. • Heat bearing points in cover to 80...100 °C (176...212 °F). • Insert input shaft (2), output shaft (3) and interme- diate shaft (1) together, at the same time.

  • Page 232: Shimming Selector Shaft

    23 00 Shimming selector shaft Important: If the housing or the complete selector shaft is re- placed, the selector shaft must be measured and shimmed. KL230380 • Measure distance “C” from the shoulder on the selector shaft to the back of the sleeve. •...

  • Page 233: Installing Selector Drum

    KR23250 23 31 Installing selector drum • Place a spacing washer of the determined thick- ness and the input-side thrust washer on selec- tor drum (7) and secure with a small amount of grease. • Swing locking lever (6) out towards the edge of the cover and install the selector drum.

  • Page 234: Installing Gearbox Housing

    Using the metering device, apply Loctite 574 23 4 700 surface sealant to the mating face of the cover. • Place assembly sleeve, BMW No. 23 4 732, on the output shaft. KR230030 • Place assembly sleeve, BMW No. 23 4 712, on the input shaft.
  • Page 235 KR230020 • Insert screws (7) and tighten in diagonally oppo- site sequence. • Install gear indicator (2) and clip cable (arrow) into position. • Install breather (1). Important: Clean metal particles off the magnet in drain plug (5). • Install oil drain plug (5). •...

  • Page 236: Aligning Rubber Mounts

    KL230050 Aligning rubber mounts 23 00 Aligning left-hand rubber mount 23 00 Important: The alignment of the left-hand rubber mounts rela- tive to the frame is preset at the factory. Do not slacken the paint-marked Torx screws (1) unless the rubber mount has to be replaced. KL230060 –...

  • Page 237: Aligning Right-Hand Rubber Mount

    Aligning right-hand rubber mount 23 00 Important: It is not necessary to re-align the right-hand rubber mount unless the gearbox, the frame or the left- hand rubber mount has been replaced. • Install the right-hand bearing bushing, but do not tighten the securing screws.

  • Page 238: Front Forks

    31 Front forks Contents Page Technical Data ..........................3 Removing/installing telescopic fork ..................5 Removing telescopic fork ......................5 Installing telescopic fork ......................7 Removing/installing fork bridge ...................9 Renewing ball joint ........................10 Removing/installing slider tube bridge ................11 Removing/installing ball joint ....................12 Disassembling/reassembling telescopic fork ............13 Disassembling telescopic fork ....................
  • Page 239 Contents Page 31.2...

  • Page 240: Technical Data

    Technical Data K 1200 RS Front suspension Type Telelever with leading link pivoted centrally on main frame. Telescopic fork Fixed fork tube surface Hard chrome plated Fixed tube extl. dia. mm (in) 34.96 f8 (1.3764) Maximum permissible fixed fork tube runout mm (in) 0.4 (0.0157)
  • Page 241 31.4...

  • Page 242: Removing/Installing Telescopic Fork

    Remove the engine spoiler and holder end screws (1) on fixed fork tube (4) at left/right. 46.14). Screws are secured with a thread-locking com- • Secure lifter, BMW No. 00 1 510, to oil sump. pound. • Loosen the left/right handlebar holder clamp (3). •...
  • Page 243 Unscrew the fastener for the leading link at the the Allen screw when removing. fork slider tube bridge, using socket wrench in- sert and internal hexagon, BMW No. 31 5 600. • • Unscrew the fastener (arrow) for the left brake Pull the telescopic fork down to remove.

  • Page 244: Installing Telescopic Fork

    Tighten left and right handlebar clamps (1). • • Secure the leading link fastener to fork slider Tighten left and right fork bridge clamps (4). • tube bridge, using socket wrench insert and in- Compress the telescopic fork. ternal hexagon, BMW No. 31 5 600. 31.7...
  • Page 245 If the telescopic fork was disassembled, fill each leg with specified quantity of oil. Capacity per fork leg ...... 0.51 l (0.90 Imp. pint/0.54 US quart) Oil grade ......BMW telescopic-fork oil Tightening torque: Oil drain plug..........13 Nm • From this point on, installation is the reverse of the removal procedure, note the following points in particular.

  • Page 246: Removing/Installing Fork Bridge

    Screw is secured with a thread-locking compound. • Undo the fork bridge fastener (3) at the frame with socket wrench insert and internal hexagon, BMW No. 31 5 600. • Take off fork bridge (10). • Installation is the reverse of the removal proce- dure.

  • Page 247: Renewing Ball Joint

    Coat the ball joint fastener with Optimoly TA and • Tighten left and right fork bridge clamps (4). secure it to the fork bridge with 46 mm (1.8110 in) socket wrench insert, BMW No. 31 5 630. Important: Install screw (3) with Loctite 243. Tightening torque: Ball joint to fork bridge .......

  • Page 248: Removing/Installing Slider Tube Bridge

    – Remove the engine spoiler and holder 46.14). • Secure lifter, BMW No. 00 1 510, to oil sump. Important: Do not operate the handbrake lever when the brake calipers have been removed. Protect painted parts from scratching: apply adhesive masking tape if necessary.

  • Page 249: Removing/Installing Ball Joint

    31 5 630 31 5 620 KR310080 • Secure sliding tube fork bridge (1) in retaining fix- ture, BMW No. 31 5 620. Warning: Note that high torque has to be applied to loosen the ball joint fastener. • Release the ball joint fastener with the 46 mm (1.8110 in) socket wrench...

  • Page 250: Disassembling/Reassembling Telescopic Fork

    KR310091 Disassembling/reassembling 31 42 telescopic fork – Before removing the telescopic fork, slacken the end plug (5). Important: – Remove telescopic fork. Avoid damage to fixed fork tube (4). Disassembling telescopic fork • 31 42 Remove fixed fork tube (4). •...

  • Page 251: Assembling Telescopic Fork

    Oil shaft sealing ring lightly and press it home on sliding tube (1), using the combined weight (ar- row) of drift, BMW No. 31 5 610, reducing adapt- er with lugs, BMW No. 31 5 613, and sleeve, BMW No. 31 5 614.

  • Page 252: Removing/Installing Front Suspension Strut

    Removing/installing front sus- 31 42 pension strut – Remove the engine spoiler and holder 46.14). • Secure lifter, BMW No. 00 1 510, to oil sump. – Remove fuel tank ( 16.5). KR310140 • Unscrew fastener (arrow) for suspension strut on frame.
  • Page 253 • Installation is the reverse of the removal proce- dure. Pay particular attention to the following: Note: If the telescopic fork was extended too far, loosen the fixed fork tube clamps and push the fixed tube into the fork tube, turning it at the same time. Note the correct projection when securing the fixed fork tube.

  • Page 254: Removing/Installing Steering Damper

    Removing/installing steering 31 42 damper Checking the steering damper – Remove front wheel ( 36.5). • – Remove left side section of fairing With the steering turned to the left, move the 46.8). front end of the piston rod radially to and fro and –...

  • Page 255: Removing/Installing Leading Link

    – Remove the engine spoiler and holder 31 5 694 46.14). • Secure lifter, BMW No. 00 1 510, to oil sump. – Remove the right-hand air intake pipe ( 46.17). • Detach the right radiator from its holder and 31 5 693 press it forward.

  • Page 256: Installing Leading Link

    M 12 threaded rod, BMW No. 31 5 691, equipment box. • M 12 nut with mount, BMW No. 31 5 692, Secure the electronic equipment box and wiring and puller sleeve, BMW No. 31 5 697, harness to the frame.

  • Page 257: Removing Left Leading Link Pivot Mount

    M12 threaded rod, BMW No. 31 5 691, • Remove angular-contact ball bearing and spacer M 12 nut with mount, BMW No. 31 5 692, sleeve, using M12 threaded rod, spacer, BMW No. 31 5 695, BMW No. 31 5 691, support, BMW No.

  • Page 258: Measuring The Leading Link

    BMW No. 31 5 682, into leading link (3). • • Undo the fastener (arrow) for the steering Stylus of gauge, BMW No. 31 5 682, must be lo- damper (2) at the leading link. cated in punch mark (arrow) in leading link on •...
  • Page 259 32 Steering Contents Page Technical Data ..........................3 Removing/installing left grip tube ..................5 Removing/installing right grip tube ..................6 Removing/installing clutch lever fitting ................7 Removing/installing brake lever fitting ................8 Removing/installing left handlebar tube .................9 Removing/installing right handlebar tube ..............10 Removing/installing left and right handlebar levers ..........
  • Page 260 Contents Page 32.2...

  • Page 261: Technical Data

    Technical Data K 1200 RS Type One-piece forged stub handlebars, adjustable from lower front to upper rear position; without anti-vibration weights Handlebar tube diameter mm (in) 22 (0.8661) Steering lock angle ° 32 Handlebar width with grip tube mm (in) 720 (28.3464)
  • Page 262 32.4...

  • Page 263: Removing/Installing Left Grip Tube

    K41320010 Removing/installing left grip 32 72 tube • [Option with heated grip] Undo cable tie. • [Option with heated grip] Separate plug connector (2) for the heated grip. • [Option with heated grip] Release cable shoes (3) from plug connector (2). •...

  • Page 264: Removing/Installing Right Grip Tube

    K41320020 Removing/installing right grip 32 72 tube • Installation is the reverse of the removal proce- • [Option with heated grip] Undo cable tie. dure. • [Option with heated grip] Separate plug – Adjust the basic throttle cable setting ( 00.36).

  • Page 265: Removing/Installing Clutch Lever Fitting

    K41320010 Removing/installing clutch 32 72 lever fitting • Installation is the reverse of the removal proce- – Take off mirror ( 00.22). dure. Pay particular attention to the following: – Remove grip tube ( 32.5). Important: Important: Make sure that lines and cables are correctly routed. Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint.

  • Page 266: Removing/Installing Brake Lever Fitting

    K41320020 Removing/installing brake lever • 32 72 Installation is the reverse of the removal proce- dure. Pay particular attention to the following: fitting – Take off mirror ( 00.22). Important: – Remove grip tube ( 32.6). Make sure that lines and cables are correctly routed. Important: Do not allow brake fluid to come into contact with Note:...

  • Page 267: Removing/Installing Left Handlebar Tube

    K41320010 Removing/installing left handle- 32 71 bar tube • Installation is the reverse of the removal proce- – Remove grip tube ( 32.5). dure. Pay particular attention to the following: • Remove multifunction switch (3) from clutch le- ver fitting (1). •...

  • Page 268: Removing/Installing Right Handlebar Tube

    K41320020 Removing/installing right han- 32 71 dlebar tube • Installation is the reverse of the removal proce- – Remove grip tube ( 32.6) dure. Pay particular attention to the following: • Remove cover (3) from brake lever fitting (1). • Remove brake light switch (2) from brake lever fitting (1).

  • Page 269: Removing/Installing Left And Right Handlebar Levers

    KR320040 Removing/installing left and Removing/installing throttle 32 72 32 72 right handlebar levers cables ( 00.36) Important: Screw is secured with a thread-locking compound. Note: When removing/installing, note springs (2). • Remove fastener (1) from left/right handlebar lever (3). • When installing, apply Loctite 243 to fastener (1) and tighten.
  • Page 270 33 Rear wheel drive Contents Page Technical Data ..........................3 Rear wheel drive - cutaway drawing .................5 Removing, disassembling, reassembling and installing rear wheel drive ..7 Removing rear wheel drive ......................7 Replacing taper roller bearing in rear wheel drive ............7 Removing input bevel pinion ......................8 Disassembling input bevel pinion ..................10...
  • Page 271 Contents Page Installing rear swinging arm ......................24 Removing/installing suspension strut ..................25 33.2...
  • Page 272 Oil changes cc 230 Drive shaft Layout 2-section double drive shaft with integral torsional vibration damper in hollow swinging arm (BMW PARALEVER), universal joints at both ends, with sliding joint at rear wheel drive end. Swinging arm Type Paralever, new swinging arm with spring strut at- tached off-centre;...
  • Page 273 33.4...

  • Page 274: Rear Wheel Drive - Cutaway Drawing

    Rear wheel drive - cutaway drawing KR330000 33.5...
  • Page 275 33.6...

  • Page 276: Removing, Disassembling, Reassembling And Installing Rear Wheel Drive

    KR330320 • Release clamping strap (1). • Pull out needle roller bearing (8) with reaction support, BMW No. 00 8 572, and internal puller, BMW No. 00 8 573. • Heat neck of housing to 120 °C (248 °F). •...

  • Page 277: Removing Input Bevel Pinion

    KR330050 • Screw rear wheel drive centrally to holder, KR330030 LT 33.043 BMW No. 33 1 510, using bearing stud (6). • Screw locking arm (7) on firmly. • • Use a tyre lever or similar tool to force off the rear Move threaded sockets (4) up to rear wheel drive shaft (1).
  • Page 278 100 °C (212 °F) and unscrew with a 36 mm Never use a hammer when slackening off hex (1.4173 in) socket wrench insert and reducing nut (4), or else the splines may be damaged. adapter, BMW No. 33 1 720. • Remove thrust ring (3). Warning: Hex nut (4) requires a high torque to loosen it.

  • Page 279: Disassembling Input Bevel Pinion

    (splines facing upwards). • To prevent the input bevel pinion (1) from being Using puller, BMW No. 00 7 500, pull off both damaged if it falls out, use a soft underlay. bearings at the same time. •...

  • Page 280: Assembling Input Bevel Pinion

    KR330120 • Pull out the outer race of the needle roller bearing using internal puller, BMW No. 00 8 573, exten- sion, BMW No. 00 8 575 and reaction support, BMW No. 00 8 570. 33 12 Installing needle roller bearing for input bevel pinion •...

  • Page 281: Installing Input Bevel Pinion

    Install shaft sealing ring (5) with the sealing lips fac- ing the input bevel pinion. • Oil shaft sealing ring (5) lightly and drive into threaded ring (6) with drift, BMW No. 33 1 760 and handle, BMW No. 00 5 500. 33.12...
  • Page 282 The nut must not damage shaft sealing ring (3). • Tighten hex nut (6) with 36 mm (1.4173 in) socket wrench insert and reducing adapter, 33 1 700 BMW No. 33 1 720. Tightening torque: Threaded ring KR330060 (clean thread + apply Loctite 577) ....118 Nm Nut for input bevel gear •...

  • Page 283: Removing Crown Wheel

    BMW No. 00 7 500. KR330180 • Clamp crown wheel (3) into vise with soft jaws. • Insert thrust block (arrow), BMW No. 33 1 307. • Using puller, BMW No. 33 1 830, pull off grooved ball bearing (2). 33.14...

  • Page 284: Installing Crown Wheel

    Heat the housing to 80 °C (176 °F). • Insert outer race (1) into bearing seat with drift, BMW No. 23 4 670, and handle, BMW No. 00 5 500. • Check that outer race is correctly fitted by strik- ing it gently.

  • Page 285: Checking/Adjusting Backlash

    (5) or insert a thick- er one if tooth backlash is insufficient. • Attach measuring fixture (2), BMW No. 33 2 600, with dial gauge, BMW No. 00 2 510, to crown wheel (3) and secure to the housing with knurled screw (4). •...

  • Page 286: Checking Tooth Contact Pattern

    Checking tooth contact pattern 33 00 KR330270 – If this contact pattern is obtained, a thinner shim KR330250 washer must be installed. Note: The tooth contact pattern must be checked if the gear set, housing or input bevel pinion bearing has been replaced.The contact pattern is adjusted by means of the shim washer (1) on the input bevel pin- ion.

  • Page 287: Shimming Housing Cover

    Oil the shaft sealing ring (31) slightly. • Using drift, BMW No. 33 1 860, and handle, 33 2 601 BMW No. 00 5 500, drive in shaft sealing ring (1). Important: Do not overheat shaft sealing ring and cord ring seal.

  • Page 288: Installing Rear Drive Shaft

    Installing rear drive shaft Installing rear wheel drive 33 00 33 10 • Coat teeth of drive pinion with Optimoly MP3. • Place the rear drive shaft on the input pinion. Important: Make sure that the circlip is correctly seated in the drive shaft.
  • Page 289 Cover of rear wheel drive housing • Hold floating bearing stud (7) with socket – Crown wheel. wrench, BMW No. 33 5 642 to prevent it turning • and tighten locknut (8) with socket, If required, check/adjust ABS sensor gap BMW No. 33 6 641.

  • Page 290: Removing, Disassembling, Reassembling And Installing Rear Swinging Arm

    • Remove circlip (1) and use socket wrench adapt- right. er, BMW No. 33 6 643, to unscrew the right • threaded ring (6). Loosen the left threaded ring (3) with socket •...

  • Page 291: Removing/Installing Flexible Gaiter

    • When installing, coat inner and outer sealing lips • (arrows) with Staburags NBU 30 PTM. Insert pressing-out tool, BMW No. 33 6 644, with pins (arrows) in the holes in the threaded ring. • Press the left/right bearing out of the threaded ring.

  • Page 292: Removing Drive Shaft

    Removing drive shaft Installing drive shaft 33 00 33 00 • Coat splines of output shaft with Optimoly MP 3. • Slide the front drive shaft (1) on to the output shaft. • Snap the circlip into position by striking the drive shaft lightly with a plastic-faced hammer.
  • Page 293 • Screw in left/right bearing studs (5). • Attach suspension strut with fastener (10) to swinging arm (11). 33 6 643 KR330410 • Using socket wrench insert, BMW No. 33 6 643, tighten left and right bearing studs (5). 33.24...
  • Page 294 Tighten the right threaded ring (6). • Tighten the left threaded ring (3). • Hold left threaded ring (3) with socket wrench, BMW No. 33 5 642 to prevent it turning and tighten locking ring (2) with socket, KR330380 BMW No. 33 6 641. •...
  • Page 295 34 Brake Contents Page Technical Data ..........................3 [Integral ABS] Removing/installing front brake caliper ..........5 [Integral ABS] Removing/installing rear brake caliper ..........5 Disassembling and assembling front brake caliper ..........6 Disassembling and assembling rear brake caliper ...........7 Disassembling rear brake caliper .....................7 Assembling rear brake caliper ....................7 [Integral ABS] Removing/installing front brake disc...
  • Page 296 Front wheel circuit only bleeding .......................21 Rear wheel circuit only bleeding ......................23 Reading the BMW MoDiTeC fault code memory ( 00.35) ........24 [Integral ABS] Performing bleed test with BMW MoDiTeC ( 00.35) .....24 [Integral II] Removing/installing front brake lines/hoses ........25 [Integral ABS] Removing front brake lines/hoses ............25...

  • Page 297: Technical Data

    Technical Data K 1200 RS as of model year 01 with Integral ABS Brake fluid DOT 4 Brake actuation hydraulic Front wheel Front brake Twin disc brake 4-piston fixed calipers with 2 floating discs Brake disc dia. mm (in) 320 (12.5984) Brake disc thickness mm (in) 5.0 (0.1969)
  • Page 298 34.4...

  • Page 299: [Integral Abs] Removing/Installing Front Brake Caliper

    [Integral ABS] Removing/ [Integral ABS] Removing/install- 3400 3400 installing rear brake caliper ing front brake caliper – Remove rear wheel ( 36.8). Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid Attention: destroys paint.

  • Page 300: Disassembling And Assembling Front Brake Caliper

    Do not insert your fingers between the pistons; risk If necessary, use the reset device, of injury. BMW No. 34 1 531, and the positioning piece, BMW No. 34 1 532, to press the pistons com- pletely back. • Insert brake pads and secure with retainers 00.42).

  • Page 301: Disassembling And Assembling Rear Brake Caliper

    RS340133 Disassembling and assembling • 3400 Remove sealing rings from left and right bores. • Inspect the brake caliper piston for hairline rear brake caliper cracks, score-marks and other damage. Disassembling rear brake caliper 3400 Assembling rear brake caliper 3400 •...

  • Page 302: [Integral Abs] Removing/Installing Front Brake Disc

    [Integral ABS] Removing/ [Integral ABS] Removing/ 3400 3400 installing front brake disc installing rear brake disc Warning: Warning: Carefully press back the pistons as you remove/in- Carefully press back the pistons as you remove/in- stall the brake callipers as the wheel circuit reservoir stall the brake callipers as the wheel circuit reservoir must not overflow.

  • Page 303: [Integral Abs] Removing/Installing Front Abs Sensor

    [Integral ABS] Removing/ 3400 installing front ABS sensor Warning: Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressu- rised. Attention: Disconnect ground lead from battery and insulate. – Remove fuel tank ( 16.5).

  • Page 304: [Integral Abs] Removing/Installing Rear Abs Sensor

    [Integral ABS] Removing/ 3400 installing rear ABS sensor – Remove rear wheel ( 36.8). Attention: Disconnect ground lead from battery and insulate. – Clean ABS sensor (2) and the hole before remov- ing/installing. KR340210 • Remove all cable ties holding the ABS sensor cable (4).

  • Page 305: [Integral Abs] Marking Rear Abs Sensor Ring

    (1). • Screw dial gauge holder, BMW No. 00 2 500, with dial gauge, BMW No. 00 2 510, and meas- KR340160 uring shoe, BMW No. 34 2 510, on to retaining bracket (1) for the ABS sensor.

  • Page 306: [Integral Abs] Removing/Installing Rear Master Brake Cylinder

    Installation is the reverse of the removal proce- dure. Pay particular attention to the following: Adjusting blow-by clearance at piston rod • Tighten non-reusable hose clip (5) with pliers, BMW No. 13 1 500. – Fill/bleed rear brake system ( 34.17). Warning: –...

  • Page 307: [Integral Abs] Removing/Installing Pressure Modulator

    [Integral ABS] Removing/ 34 51 installing pressure modulator Attention: Work on the ABS pressure modulator may only be performed by a specialist workshop. Attention: Do not allow brake fluid to come into contact with painted parts of the motorcycle. Brake fluid destroys the paint finish.
  • Page 308 KR340752 • • Loosen pressure modulator. Installation is the reverse of the removal proce- dure. Pay particular attention to the following: Note: Always replace the seals (arrow) between the brake lines and the pressure modulator when you replace the pressure modulator or brake lines. Warning: Always replace the springs (10).

  • Page 309: Disassembling Pressure Modulator, Removing/Installing Brake Lines

    KR340752 Disassembling pressure modulator, Removing/ installing brake lines • Unfasten the clips (5, 6). • Warning: Pull off the front and rear brake fluid hoses (7,8). Always replace the springs (10). Ensure correct positioning. Note: Prepare the old pressure modulator for transport by Note: plugging all openings.

  • Page 310: [Integral Abs] Draining Brake System

    [Integral ABS] Draining wheel cir- 3400 After switching on the ignition, always wait for the cuit BMW Integral ABS to complete its self-diagnosis. Do not operate the brake lever until self-diagnosis has completed. Note: The Integral ABS brake system has four independ- •...

  • Page 311: [Integral Abs] Filling Brake System

    The wheel circuit is filled via the brake caliper to en- • sure that the system is free of air bubbles. Connect bubble-free injector, BMW No. 34 2 551, to bleed screw of left brake caliper. • Warning: Open the bleed screw (6).

  • Page 312: Filling Rear Wheel Circuit

    Completely fill injector, BMW No. 34 2 551, and Filling rear wheel circuit silicon hose with brake fluid. • Connect bubble-free injector, BMW No. 34 2 551, to bleed screw of right brake caliper. • Open the bleed screw. •...

  • Page 313: [Integral Abs] Filling Control Circuit

    [Integral ABS] Filling control 3400 – Connect the silicon hose with bleeding device to each of the 3 bleed screws in turn, circuit - front dosing cylinder - front integral circuit Note: - front control circuit Only check the brake system after bleeding of all •...

  • Page 314: Filling The Rear Control Circuit

    Filling the rear control circuit Bleeding rear control circuit ( 00.55) Note: The rear wheel circuit and control circuit have a shared expansion tank. The rear wheel circuit must be filled from the brake calliper ( 34.18). KR340570 • Top up the reservoir (2) to the MAX mark. Attention: During the process, the brake fluid level in the res- ervoir must not drop below the hose level (arrow, or...

  • Page 315: [Integral Abs] Wheel Circuit, Only Bleeding

    (1). • at the brake caliper and bled once again ( 34.17). Connect silicon hose, BMW No. 34 1 560, to bleed nipple of left brake caliper and to cap, BMW No. 34 2 541. Front wheel circuit only bleeding Note: If required, secure bleed hose with cable tie.
  • Page 316 Bleed screw to brake caliper ......7 Nm wheel circuit reservoir. • Connect silicon hose, BMW No. 34 1 560, to bleed nipple of right brake caliper. • The procedure for bleeding the right brake cali- per is the same as that for the left caliper.

  • Page 317: Rear Wheel Circuit Only Bleeding

    Fill the rear wheel-circuit reservoir with as much brake fluid as it will take. Note: • Screw cap, BMW No. 34 2 541, onto rear wheel The bleed process runs via the pump in the pres- circuit reservoir. sure modulator.

  • Page 318: [Integral Abs] Performing Bleed Test With Bmw Moditec ( 00.35)

    Close the bleed screw. • Release the brake lever. • Switch off the ignition. • Disconnect silicon hose, BMW No. 34 1 560, from bleed screw and drain its contents into wheel circuit reservoir. • Remove cap, BMW No. 34 2 541. Attention:...

  • Page 319: [Integral Abs] Removing Front Brake Lines/Hoses

    41340010 [Integral ABS] Removing/install- 3400 Attention: ing front brake lines/hoses Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid [Integral ABS] Removing front brake destroys paint. Wrap cloths around the ends of the lines/hoses pressure lines to prevent residual brake fluid escap- ing.
  • Page 320 Attention: After all the work on the brake system has been completed, run a bleed test using the BMW MoDiTeC! • Perform bleed test with BMW MoDiTeC 00.35). Brake fluid............DOT 4 Tightening torque: Brake hose/line/banjo bolt ......18 Nm Brake fluid distributor to holder ...... 9 Nm Holder to sliding tube ........

  • Page 321: [Integral Abs] Removing/Installing Rear Brake Lines/Hoses

    41340020 [Integral ABS] Removing/ 34 00 Attention: installing rear brake lines/hoses Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid [Integral ABS] Removing brake lines/ destroys paint. Wrap cloths around the ends of the hoses pressure lines to prevent residual brake fluid escap- ing.
  • Page 322 After all the work on the brake system has been completed, run a bleed test using the BMW MoDiTeC! KR340710 • Perform bleed test with BMW MoDiTeC • Open disposable clips (1,2) on supply tank 00.35). – Remove pressure modulator (3) ( 34.13).

  • Page 323: Removing/Installing Hose With Cap Of Wheel Circuit Reservoir

    Removing/installing hose with [Integral ABS] Checking brake pads 34 00 for wear/replacing ( 00.41) cap of wheel circuit reservoir [IntegralABS] Checking brake fluid level at handlebar fitting ( 00.43) [Integral ABS] Changing brake fluid in the wheel circuit ( 00.45) [Integral ABS] Changing brake fluid K41340040 in the control circuit (...
  • Page 324 36 Wheels and tyres Contents Page Technical Data ..........................3 Removing/installing front wheel ..................5 Removing/installing wheel bearings .................6 Removing left/right wheel bearings ..................6 Installing right/left wheel bearing .....................7 Installing left wheel bearing .........................7 Installing right wheel bearing .......................7 Removing/installing rear wheel ....................8 Removing rear wheel ........................8...
  • Page 325 Contents Page 36.2...

  • Page 326: Technical Data

    Technical Data K 1200 RS Rim size Front 3.50"x17" MT H 2 Rear 5.00"x17" MT H 2 [Option] rear 5.50"x17" MT H 2 Max. vertical runout Front mm (in) 0.5 (0.0197) Rear mm (in) 0.3 (0.0118) Max. lateral runout Front mm (in) 0.5 (0.0197)
  • Page 327 36.4...

  • Page 328: Removing/Installing Front Wheel

    • Grease the quick-release axle (1) and bearing – Raise the front wheel with the front wheel stand, cover (3) lightly with Shell Retinax EP2. BMW No. 36 9 970. – Remove front section of front mudguard. 46.6) Note: Tighten the quick-release axle (1) first, then the left clamping screw (2).

  • Page 329: Removing/Installing Wheel Bearings

    Lever out shaft seal (1). • Remove circlip (2) with suitable pliers. KR360060 • Place support ring, BMW No. 36 6 640, on wheel hub. • Heat bearing seat to 60 °C (140 °F). • Pull out wheel bearing (3) with puller, BMW No.

  • Page 330: Installing Right/Left Wheel Bearing

    Heat bearing seat to 60 °C (140 °F). • Drive wheel bearing (3) in with handle for drift, BMW No. 00 5 500, and drift, BMW No. 36 5 512, as far as the inner ring of spacing sleeve (4). KR360021 00 5 500...

  • Page 331: Removing/Installing Rear Wheel

    KR360030 Removing/installing rear wheel • 36 30 Working in diagonally opposite sequence, tight- en the outer wheel studs to 50 Nm. Removing rear wheel • Fully tighten the screw in the centre. 36 30 • Fully tighten the outer wheel studs in diagonally –...

  • Page 332: Static Balancing Of Front And Rear Wheels

    Static balancing of front wheel 36 30 The rear wheel can also be balanced dynamically. – Align the balancer, BMW No. 36 3 600, with knurled screws (2)/spirit level (1). – Align the balancer, BMW No. 36 3 600, with •...

  • Page 333: Checking Front/Rear Wheel Rim For Runout

    36 32 for runout Checking front wheel rim for 36 32 Note: runout Apply the dial gauge, BMW No. 00 2 510, only to the machined inner surface of the wheel rim. – Remove tyre. • – Align the balancer, BMW No. 36 3 600, with Measure vertical or horizontal runout, as applica- knurled screws (2)/level gauge (1).

  • Page 334: Checking Rear Wheel Rim For Run-Out

    Remove tyre. Note: – Align the balancer, BMW No. 36 3 600, with Apply the dial gauge, BMW No. 00 2 510, only to knurled screws (2)/level gauge (1). the machined inner surface of the wheel rim. • Attack the mounting device, BMW No. 36 3 618, •...
  • Page 335 46 Frame Contents Page Technical Data ..........................3 General view of body panels ....................5 Removing/installing mudguards ..................6 Removing/installing front mudguard ..................6 Removing/installing tail section ....................7 Removing/installing rear carrier section ................7 Removing/installing fairing side section .................8 Removing/installing left/right inner trim .................8 Removing/installing upper section of fairing ...............9 Removing left and right fairing side sections ..............10...
  • Page 336 Contents Page Removing/installing lock carrier ....................19 Removing/installing main stand/side stand ..............20 Disassembling and assembling side stand ...............20 Removing/installing pivot mount with centre (main) and side stands ....20 Removing/installing main (centre) stand ( 00.71) ............20 Removing/installing footrest system ................21 Removing/installing right footrest system ................21 Removing/installing brake pedal ....................21...

  • Page 337: Technical Data

    Technical Data K 1200 RS Location of type plate/vehicle identification Left rear frame, inside/bottom right of frame number (remove seat) Length, overall mm (in) 2,250 (88.5825) Maximum height in normal position mm (in) 1,248 (49.1338) (without mirrors, windscreen lowered) Width across handlebars mm (in) 680 (26.7716)
  • Page 338 46.4...

  • Page 339: General View Of Body Panels

    General view of body panels K41469010 46.5...

  • Page 340: Removing/Installing Mudguards

    KR460010 Removing/installing mud- 46 60 guards Removing/installing front mud- 46 61 guard Note: To remove or install the rear section, the front sec- tion has to be removed first. Important: When installing the rear section of the front mud- guard, centre it relative to the wheel. Tightening torque: Front section to rear section of front mudguard: to slider tube, top ...........

  • Page 341: Removing/Installing Tail Section

    Removing/installing tail section Removing/installing rear carrier 46 62 46 62 section K41460070 K41460080 • [Option, case carrier without luggage rack] Detach the left and right case carriers from the – Remove the seat ( 52.5). • frame and the grab handles. [Activated charcoal filter] Undo the cable tie for •...

  • Page 342: Removing/Installing Fairing Side Section

    K41460050 Removing/installing fairing side 46 63 section Removing/installing left/right inner 46 63 trim • Detach and remove left/right inner trim (1). • Installation is the reverse of the removal proce- dure. Note: When installing, make sure that the lug (arrow) is correctly seated.

  • Page 343: Removing/Installing Upper Section Of Fairing

    K41460040 Removing/installing upper section 46 63 of fairing – Remove inner trim panels ( 46.8). • Remove upper section of fairing (1). • Remove left/right lamp sockets (2) from upper section of fairing. • Installation is the reverse of the removal proce- dure.

  • Page 344: Removing Left And Right Fairing Side Sections

    K41460030 Removing left and right fairing • 46 63 Installation is the reverse of the removal proce- dure. side sections – Remove the seat ( 52.5). – Remove inner trim panels ( 46.8). Important: – Remove upper section of fairing ( 46.9).

  • Page 345: Removing/Installing Windscreen

    K41UB0020 Removing/installing winds- 46 63 creen Note: The windscreen can be set manually to two positi- ons. • Raise the windscreen (1). • Press out pins (2) towards the motorcycle’s cen- treline and take off the windscreen. Important: Do not re-use the pins. •...

  • Page 346: Removing/Installing Cover For Windscreen Holder

    K41460051 Removing/installing cover for 46 63 windscreen holder – Remove windscreen ( 46.11). – Remove inner trim panels ( 46.8) • Remove covers (1) of left and right windscreen holders. • Installation is the reverse of the removal proce- dure. Note: When installing, make sure that the lug (arrow) is correctly seated.

  • Page 347: Removing/Installing Instrument-Panel Trim

    K41460040 Removing/installing instrument- 46 63 panel trim – Remove windscreen ( 46.11). – Remove inner covers ( 46.8). – Remove covers of windscreen holders 46.12). – Remove upper section of fairing (1) ( 46.9). • Release instrument-panel trim (3). • Slacken screws (4) and push bottom windscreen holder up in direction indicated by arrow.

  • Page 348: Removing/Installing Engine Spoiler

    Removing/installing engine Removing/installing bracket for 46 63 46 63 engine spoiler spoiler – Remove engine spoiler. KR460110 KR460120 • Detach the engine spoiler from the left/right side • sections and from front left engine spoiler brack- Take out screws (arrows) at left and right and re- move the engine spoiler bracket (2) downwards.

  • Page 349: Removing/Installing Left/Right Tail Side Section

    Removing/installing left/right 46 63 tail side section – Remove the seat ( 52.5). • [Option pannier case carrier] Detach the left/ right pannier case carrier at the front. KR460140 • Detach the left/right tail side section. Note: The tail side section is a push fit at the front (arrow). •...
  • Page 350 KR460180 Removing/installing fairing car- • 46 63 Release the cable ties, guide the instrument cluster with wiring harness through the fairing rier carrier and set it down on the frame. • – Remove windscreen ( 46.11). Detach the radiators at left and right from their –...

  • Page 351: Removing/Installing Air Guide

    Removing/installing air guide Removing/installing intake air 46 63 13 72 pipe – Remove left side section of fairing ( 46.8). Important: Comply with safety precautions when handling or working with fuel. – Release fasteners and pull back the fuel tank 16.5).

  • Page 352: Removing/Installing Discharge Air Guide For Left/Right Radiators

    Removing/installing discharge Removing/installing tail com- 46 63 46 00 ponents air guide for left/right radiators – Remove left and right fairing side sections Removing/installing grab handle 52 53 46.8). – Remove the seat ( 52.5). • Remove the left/right tail side sections. KR170130 KR460200 •...

  • Page 353: Removing/Installing Lock Carrier

    [Option] Removing/installing lug- Removing/installing lock carrier 46 54 52 53 gage rack – Remove the seat ( 52.5). – Remove the seat ( 52.5). KR460240 KR460220 • Remove screws (arrows) and pull the lock carrier • Detach the left/right case carriers from the lug- to the right to remove.

  • Page 354: Removing/Installing Main Stand/Side Stand

    – Remove engine spoiler holder ( 46.14). • Secure lifter, BMW No. 00 1 510, to oil sump. • Raise the motorcycle until the centre stand can move freely. • Disconnect the cable tie, disconnect the plug for the side stand switch and guide the cable through downwards.

  • Page 355: Removing/Installing Footrest System

    K41460200 Removing/installing footrest 46 71 Important: system Screw is secured with a thread-locking compound. Removing/installing right footrest 46 71 • Detach brake pedal (1) from the footrest plate system and remove it with the torsion spring, bearing bushing and washer. •...

  • Page 356: Removing/Installing Left Footrest System

    Removing/installing footrest 46 71 Lubricant: ..........Shell Retinax EP 2 • Remove lock washer, pin and torsion spring; take off footrest. Tightening torque: Footrest to frame.......... 20 Nm Note: Footrest pad to footrest........4 Nm When installing pin for footrest, grease with Shell Retinax EP 2.

  • Page 357: Removing/Installing Rear Left Footrest Holder

    Removing/installing rear left foot- Removing/installing rear right 46 71 46 71 rest holder footrest holder KR460300 KR460330 • • Unscrew nut for battery holder. Remove the retaining plate for the brake lines (ar- • Take out screws (arrows) and remove footrest row) at the footrest holder.

  • Page 358: Removing/Installing Rear Frame

    Removing/installing rear frame • 46 51 Remove the battery holder from the rear frame on the right. Important: Disconnect the negative battery terminal first, then the positive terminal. Connect the positive battery terminal first, then the negative terminal. • Disconnect ground lead from battery and insu- late.

  • Page 359: Removing/Installing Frame

    46.14). 46 51 – Remove engine spoiler holder ( 46.14). • Secure lifter, BMW No. 00 1 510, to oil sump. Note: Before removing the cross-tube, remove either the exhaust system ( 18.5) or the rear swinging arm 33.21). KR460510 •...

  • Page 360: Removing/Installing Frame

    Remove engine spoiler holder ( 46.14). – Remove rear swinging arm ( 33.21). • Secure lifter, BMW No. 00 1 510, to oil sump. – Remove the rear suspension strut ( 33.25). • Disconnect plugs for ignition signal transmitter and oil pressure switch and guide the cables through downwards.
  • Page 361 – Remove the rear left footrest holder ( 46.23) • Remove the fasteners for the battery carrier, and remove the rear brake fluid reservoir, brake hos- es and battery carrier together with the pressure modulator. • Disconnect the plugs for the gear indicator switch, temperature sensor at cylinder head, side stand switch and oxygen sensor, and guide the cables through downwards.
  • Page 362 • Installation is the reverse of the removal proce- Rear footrest holder, right, to frame ..... 21 Nm dure. Engine spoiler: Lower bracket for engine spoiler to engine... 22 Nm Note: Engine spoiler to lower bracket ...... 9 Nm See table below for correct order of assembly. Fairing carrier: Left and right to frame ........

  • Page 363: Lifting Frame

    Lifting frame 46 00 Remove fuel tank ( 16.5). – Disconnect the plug for the immersion-tube sen- sor. Note: – Disconnect the plug for the fuel pump. Valid for the following tasks only: Removing starter/alternator Removing clutch/gearbox Warning: Removing engine Comply with safety precautions when handling or working with fuel.
  • Page 364 Securing lifter to sump. Remove cross-tube ( 46.25). • Secure lifter, BMW No. 00 1 510, to sump. – Open the retaining hoop and disconnect the gear shift lever. Remove rear wheel ( 36.8). – Remove the left footrest assembly.

  • Page 365: Lowering The Frame

    Before lowering the frame, install the earth (ground) leads at the starter. • Using crane, BMW No. 46 5 640, raise the frame at the rear just far enough to permit access to the gearbox, starter and alternator. Important:...
  • Page 366 Connect the coolant hose to the coolant stub Use special socket wrench insert, pipe at the bottom of the right-hand radiator. BMW No. 33 6 641, with opening for locking ring – Fill the cooling system. socket wrench, BMW No. 33 6 642, to prevent the threaded ring from turning.
  • Page 367 • Connect the hose for the crankcase breather to Install the fairing. • the crankcase. Detach lifter, BMW No. 00 1 510, from sump. • Connect plug for throttle-valve actuator and plug – Install engine spoiler ( 46.14).

  • Page 368: Supporting The Frame

    Remove transverse tube ( 46.25). bush. • • Secure frame support, BMW No. 46 5 660, to Drive out the threaded bush using handle for the mounting points (1) for the transverse tube. drift, BMW No. 00 5 500 and drift, •...

  • Page 369: Installing Threaded Bushes

    46 5 732 46 5 734 46 5 733 KL460430 • .Install M8 alignment pin, BMW No. 46 5 734. KL46046 Important: Note: When applying heat, always take care not to dam- Grub screw (1) is secured with thread-locking com- age cables and lines and rubber and plastic compo- pound;...

  • Page 370: Measuring Wheel Track Offset

    • Place track alignment gauge, Note: BMW No. 36 3 920, against the left or right side The average of these two values less the width of of the motorcycle. the track alignment gauge is measured value “B”.
  • Page 371 • Calculate wheel track offset “S”: EXAMPLE: Wheel track offset “S” is the distance to left or right   Formula: - - - - - – - - - - between the longitudinal axes of the front and rear ...
  • Page 372 51 Equipment Contents Page Removing/installing ignition switch/steering lock ............3 Removing/installing lock barrel ....................3 Removing/installing fuel tank lock barrel ...............4 Removing/installing seat lock ....................5 Removing/installing mirror ( 00.22) .................5 51.1...
  • Page 373 Contents Page 51.2...

  • Page 374: Removing/Installing Ignition Switch/Steering Lock

    Pay particular attention to the following: Removing lock barrel if ignition key has broken • Tighten the non-removable screws with steering lock socket wrench insert, BMW No. 51 0 531. Important: Tightening torque: When drilling (without removing the fork bridge) trap Non-removable screw ........

  • Page 375: Removing/Installing Fuel Tank Lock Barrel

    Removing/installing fuel tank • 51 25 Grease new lock barrel with Shell Retinax EP2. • Install lock barrel with key (at a right angle to di- lock barrel rection of travel). • Further installation is the reverse of the removal –...

  • Page 376: Removing/Installing Seat Lock

    Removing/installing seat lock Removing/installing mirror 51 25 51 16 00.22) • [Option case carrier] Remove the left-hand case carrier with the seat lock. KR460230 • [Option case carrier] Press keeper (arrow) into lock barrel. • Remove lock carrier and press keeper into lock barrel through the small hole in the lock carrier.
  • Page 377 52 Dualseat Contents Page Technical Data ..........................3 Removing seat ..........................5 Installing seat ..........................5 Adjusting seat ..........................5 Removing/installing seat lock ( 51.5) ................5 52.1...
  • Page 378 Contents Page 52.2...
  • Page 379 Technical Data K 1200 RS Height of seat at unladen weight Seat mm (in) 800 (31.4960) bottom mm (in) 770 (30.3149) Comfort seat mm (in) 820 (32.2834) bottom mm (in) 790 (31.1023) 52.3...
  • Page 380 52.4...
  • Page 381 K41520010 Removing seat Adjusting seat 52 53 52 53 • Turn the key in the seat lock anti-clockwise and hold it there. Important: • Pull the seat upwards and to the rear out of its When installing, make sure that the seat is retained catch, as far as the first detent position.
  • Page 382 61 General electrical equipment Contents Page Technical Data ..........................3 Removing/installing battery ( 00.69) ................5 Removing/installing battery holder ..................5 Removing/installing electronic equipment box ............5 Wiring harness ..........................6 View from right ..........................6 View from left .............................7 View from front ..........................8 Relay positions in electronic equipment box ...............9 Renewing left multifunction switch and clutch switch ...........10...
  • Page 383 Contents Page Removing/installing gear indicator ..................20 61.2...

  • Page 384: Technical Data

    Technical Data K 1200 RS Circuit voltage V 12 Battery Amp/h 19 61.3...
  • Page 385 61.4...

  • Page 386: Removing/Installing Battery ( 00.69)

    Removing/installing battery 61 21 00.69) Removing/installing battery 61 21 holder – Remove pressure modulator ( 34.13). • Remove the fasteners for the battery holder. Re- move the battery holder. Tightening torque: KR610040 Battery holder to frame........6 Nm Battery holder to cross-tube, M6....6 Nm •...

  • Page 387: Wiring Harness

    Wiring harness View from right 61.6...

  • Page 388: View From Left

    View from left 61.7...

  • Page 389: View From Front

    View from front K41610010 61.8...
  • Page 390 KR610081 Relay positions in electronic equip- ment box – Control unit for fuel level warning light (1) – Flasher relay (2) – Motronic relay (3) – Horn relay (4) – Fan relay (5) – Starter module (6) – ABS warning relay (7) –...

  • Page 391: Renewing Left Multifunction Switch And Clutch Switch

    Renewing left multifunction switch 61 31 and clutch switch – Remove the discharge-air guide from the right- hand radiator ( 46.18). – Press radiator out of holder. – Remove the right-hand air intake pipe 46.17). KR610110 • Open the cable ties (arrows). KR610090 •...
  • Page 392 K41320010 • Release fasteners (6) and take off lower 61 31 Removing left multifunction switch • cover (5). Disconnect plug for multifunction switch (8) in electronic equipment box. • 61 31 Removing/installing clutch switch Release the fastener (4). • Take off multifunction switch (3) with cable. •...

  • Page 393: Renewing Right Multifunction Switch And Brake Switch

    Renewing right multifunction 61 31 switch and brake switch – Remove the air output from the right-hand radia- tor ( 46.18). – Press radiator out of holder. – Remove the right-hand air intake pipe 46.17). KR610170 • Open the cable ties (arrows). KR610090 •...
  • Page 394 K41320020 • Release fasteners (3) and take off lower 61 31 Removing/installing right multifunction cover (4). switch • Separate the plug connector (7) at the multifunc- 61 31 Removing brake light switch tion switch. KR610130 KR620020 • • Disconnect plug (8). Disconnect plug (9).

  • Page 395: Removing/Installing Fuse Box

    Removing/installing fuse box 61 13 – Remove the seat ( 52.5). KR610260 • Turn the holder and take it off. • Installation is the reverse of the removal proce- K41610020 dure. Removing/installing power socket • Pull the fuse box up at the clip (arrow) to remove. 61 13 –...

  • Page 396: [Without Integral Abs] Removing/Installing Inductive Signal Transmitter For Speedometer

    KR610220 Inductive sensor (3) to rear wheel drive ..4 Nm Renewing ABS sensor at front/ • 34 52 Install temperature sensor (2) with special wrench, BMW No. 00 2 800. rear – Remove/install front ABS sensor ( 34.9). –...

  • Page 397: Replacing Side Stand Switch

    Replacing side stand switch 61 31 Check operation of side stand switch ( 00.71) 61 31 Removing/installing side stand switch KR610350 • Disconnect plug (arrow). • Open the cable ties. KR610360 • Release the fastener (arrow). • Remove side stand switch with cable. •...

  • Page 398: Renewing/Adjusting Foot Brake Light Switch

    Renewing/adjusting foot brake • 61 31 Installation is the reverse of the removal proce- dure. Pay particular attention to the following. light switch – Remove the right footrest assembly ( 46.21). Tightening torque: Brake-light switch to footrest plate....5 Nm Important: Make sure that the cable is routed correctly at the cutout (arrow) in the footrest plate.

  • Page 399: Removing/Installing Ignition Switch/Steering Lock Cable

    Removing/installing ignition 61 31 switch/steering lock cable – Remove the right side section of the fairing 46.8). KR610130 • Open the lid of the electronic equipment box. • Disconnect plug (arrow). • Installation is the reverse of the removal proce- KR610340 dure.

  • Page 400: Removing/Installing Oil Pressure Switch/Cable For Temperature Sensor At Water Pump

    Removing/installing oil pressure 61 31 switch/cable for temperature sensor at water pump – Remove the right side section of the fairing 46.8) and the engine spoiler ( 46.14). – Remove the cover from the Hall-effect transmit- ter ( 12.5). • Open the lid of the electronic equipment box.

  • Page 401: Removing/Installing Horn

    Removing/installing horn Removing/installing gear indicator 61 33 23 14 – Remove the air guide at the left radiator 46.17). KR610150 K41610030 • Disconnect plug (arrow). • Open the cable ties. • Disconnect plug (2). • Release cable tie (3). • Release fastener (1) and take off the horn.
  • Page 402 62 Instruments Contents Page Technical Data ..........................3 Removing/installing instrument panel ................5 Wiring colours ...........................5 Removing/installing instrument cluster .................6 Replacing telltale/warning lights ....................7 Removing/installing wiring harness ...................8 62.1...
  • Page 403 Contents Page 62.2...
  • Page 404 Technical Data K 1200 RS Instrument cluster Turn indicator repeaters 12V 1.7W DIN 72 601 Other telltale lights, instrument lighting 12V 1.7W DIN 72 601 ABS warning light 12V 3W DIN 72 601 62.3...
  • Page 405 62.4...
  • Page 406 10 11 12 13 14 19 18 17 16 15 KR620071 Removing/installing instrument 62 11 panel Wiring colours – brown (1) – black (2) – green-black (3) – grey-blue/brown-blue (4) – brown/red-brown (5) – blue-green (6) – yellow (7) – yellow-violet (8) –...
  • Page 407 Removing/installing instrument • 62 11 Install the contacts and telltale/warning lights in the new instrument cluster according to the cor- cluster rect colours. • – Remove left/right inner trim panels ( 46.8). Reconnect the digital display plug. • Press the instrument cluster into its holder. •...
  • Page 408 14 13 12 11 K41620010 Replacing telltale/warning lights 62 99 – Disassemble the instrument cluster to the point at which the telltale/warning lights are accessi- – Tachometer, temperature gauge light (1) ble. – Speedometer, tachometer light (2) – Right flashing turn indicator repeater (3) –...
  • Page 409 Removing/installing wiring har- 62 11 ness – Remove the intake air pipe ( 46.17). – Remove the air outlet guide for the right-hand ra- diator ( 46.18). • Press radiator out of holder. Kr610100 • Release cable ties (arrows) at wiring harness. KR620010 •...
  • Page 410 63 Lights Contents Page Technical Data ..........................3 Removing/installing headlight ....................5 Adjusting headlight ( 00.26) ....................5 Replacing bulbs in headlight ....................6 Renewing front turn indicators .....................6 Removing/installing front turn indicator .................6 Changing the bulb ..........................6 Renewing rear lights ........................7 Removing/installing rear/brake light housing ..............7 Removing/installing turn indicator housing .................7...
  • Page 411 Contents Page 63.2...
  • Page 412 Technical Data K 1200 RS Lights Headlight H7 tandem headlight with free-form reflector and manual beam throw adjustment Bulbs High (main) beam headlight H3 halogen bulb, 12V 55W, asymmetric, Low (dipped) beam headlight H7 halogen bulb, 12V 55W, asymmetric Parking light...
  • Page 413 63.4...

  • Page 414: Removing/Installing Headlight

    K41630011 Removing/installing headlight Adjusting headlight ( 00.26) 63 12 63 10 – Remove upper section of fairing ( 46.9). • Disconnect plug (1). • Pull side light (2) out of the headlight. • Release fasteners (3) for headlight from fairing carrier.

  • Page 415: Replacing Bulbs In Headlight

    Replacing bulbs in headlight Renewing front turn indicators 63 12 63 13 Removing/installing front turn 63 13 indicator Note: Never touch the glass of the bulb with the fingers. K41630030 KR630020 • Release the fastener (1) and remove the turn in- •...

  • Page 416: Renewing Rear Lights

    Renewing rear lights 63 21 Important: When changing the rear and brake light bulbs, do not accidentally confuse their contacts. KR630031 KR630070 Removing/installing rear/brake 63 21 light housing Cable colours at contacts grey-yellow (1) • Release the fasteners (1) and pull the rear/brake brown (2) light housing (2) off to the rear.

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