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K 1200RS
BMW K 1200RS Manuals
Manuals and User Guides for BMW K 1200RS. We have
2
BMW K 1200RS manuals available for free PDF download: Repair Manual
BMW K 1200RS Repair Manual (416 pages)
Brand:
BMW
| Category:
Motorcycle
| Size: 54.08 MB
Table of Contents
00 Tightening Torques, Operating Fluids
10
Tightening Torques
4
Key to Symbols
4
Pre-Delivery Check
6
Engine
7
12 Engine Electrics
8
13 Fuel Preparation and Control
8
16 Fuel Tank and Lines
8
Table of Contents
10
Tightening Torques
12
Engine Electrics
13
Fuel Preparation and Control
14
17 Radiator
15
21 Clutch
15
23 Transmission
16
31 Front Fork
17
32 Steering
18
Rear Wheel Drive
18
Brakes [Integral ABS]
19
Brakes [Optional Extras, Without Integral ABS]
20
36 Wheels and Tyres
20
Frame
22
Equipment
22
61 General Electrical Equipment
23
62 Instruments
23
63 Lights
23
Table of Operating Fluids
24
00 Pre-Delivery Check
26
General View of Crated Motorcycle
28
Checking the Shipping Crate for Damage
29
Damage Discovered in Germany
29
Damage Discovered in Importer Markets
29
General Instructions
30
Pushing the Motorcycle Onto a Workshop Platform
30
Inspecting Motorcycle for Damage
30
Unpacking the Motorcycle
30
Checking that Delivery Is Complete
30
Installing Remaining Items on Motorcycle
31
Installing the Windscreen
31
Installing Mirrors, Left/Right
31
Installing Bracket for Engine Spoiler
32
Installing the Engine Spoiler
32
Filling and Charging the Battery
33
Remove the Battery
33
Installing the Battery
33
Checking Tyre Pressures
34
Checking Tightness of Rear Wheel Studs
34
Checking and Adjusting the Motorcycle
35
Checking the Function of Side Stand Contact Switch
35
Checking the Headlight Beam Setting and Adjusting if Necessary
35
Vertical Adjustment
35
Lateral Adjustment
35
Installing the Seat
36
Adjusting Seat
36
Adjusting the Handlebars, Left/Right
36
Adjusting Footrests Left/Right
37
Adjusting Gearshift Lever
37
[Integral ABS] Performing Bleed Test with BMW Moditec
38
Final Inspection and Function Check
38
Final Cleaning
38
Maintenance
38
Handover
39
00 Maintenance
40
[Integral ABS] Perform Bleed Test with BMW Moditec
44
(Inspections II and III)
44
Maintenance
44
Reading the BMW Moditec Fault Code Memory
44
(Inspections I, II, III and IV)
44
Key to Maintenance Intervals
44
General Instructions
44
Pushing the Motorcycle Onto a Workshop Platform ( a 00.21)
44
Checking Throttle Cable Play, Adjusting if Necessary
45
(Inspections I and III)
45
[Cruise Control] Models with Cruise Control
46
Throttle-Opener Cable, Throttle-Closer Cable
46
Cruise-Control System Cable
46
[Cruise Control] Turning Throttle Twistgrip Relative to Throttle-Valve Shaft
47
Cruise-Control System Does Not Switch off
47
Cruise-Control System Cannot be Set, or Continually Shuts down
47
Changing Engine Oil, Replacing Oil Filter Element
48
(Inspections I, II, III and IV)
48
Gearbox Oil Change
49
(Inspection III)
49
Rear Wheel Drive Oil Change (Every 40,000 Km/24,000 Miles)
49
(Inspections I and III)
49
[Integral ABS] Checking Brake Pads/Brake Discs for Wear/Replacing if Necessary
50
(Inspections II and III)
50
[Integral ABS] Checking Front Brake Pads for Wear
50
[Integral ABS] Checking Rear Brake Pads for Wear
50
[Integral ABS] Checking Brake Discs for Wear
50
[Integral ABS] Replacing Brake Pads
51
Replacing Front Brake Pads
51
Replacing Rear Brake Pads
52
[Integral ABS] Checking Brake Fluid Level at Handlebar Fitting
52
(Inspections II and III)
52
[Integral ABS] Checking Operation of Brake System and Freedom from Leaks; Repairing if Necessary
53
(Inspection III)
53
[Integral ABS] Changing Brake Fluid in Wheel Circuit/Bleeding
54
(Inspection IV) Annual
54
[Integral ABS] Preliminary Work - Front/Rear Wheel Circuit
54
[Integral ABS] Replacing Brake Fluid in the Front Wheel Circuit/Bleeding
54
Force the Front Brake Pistons Back
54
Change the Front Brake Fluid/Bleeding
55
[Integral ABS] Reservoir Filling Instructions for Front Wheel Circuit
56
[Integral ABS] Replacing Brake Fluid in the Rear Wheel Circuit/Bleeding
57
Force the Brake Pistons Back
57
Change the Rear Brake Fluid/Bleeding
58
Control Circuit
59
[Integral ABS] Replacing Brake Fluid in the Control Circuit/Bleeding
60
(Inspection IV) Every 2 Years
60
[Integral ABS] Preliminary Work - Front/Rear Control Circuit
60
[Integral ABS] Replacing Brake Fluid in the Front Control Circuit/Bleeding
61
Bleeding the Control Circuit at the Filler Adapter
62
Front Metering Cylinder
62
Front Integral Circuit
62
Front Control Circuit
63
Front Metering Cylinder (See Above)
63
[Integral ABS] Filling Front Control Circuit to Specified Level
63
[Integral ABS] Replacing Brake Fluid in the Rear Control Circuit/Bleeding
64
Rear Metering Cylinder
64
Rear Integral Circuit
65
Rear Control Circuit
65
Front Dosing Cylinder (See Above)
65
Installation
65
[Integral ABS] Filling Brake-Fluid Reservoir for Rear Wheel Circuit and Rear Control Circuit
65
[Integral ABS] Performing Bleed Test with BMW Moditec ( 00.35)
65
(Inspection IV) Annual
65
[Option Without Integral ABS] Checking Brake Fluid Level Front and Rear
66
(Inspections II and III)
66
Checking Brake Fluid Level (Front Brakes) at Handlebar Fitting
66
Checking the Rear Brake Fluid Level
66
[Option Without Integral ABS] Changing Brake Fluid and Bleeding the Brake System
67
(Inspection IV) Annual
67
Front Brake
67
Force Back the Brake Pistons
67
Change and Bleed the Front Brake Circuit
67
Bleeding the Front Left Brake Caliper
68
Bleeding the Front Right Brake Caliper
68
Rear Brake
69
Force Back the Brake Pistons
69
Change and Bleed the Rear Brake Circuit
69
Checking Clutch Fluid Level, Correcting if Necessary
70
(Inspections II and III)
70
Changing the Clutch Fluid/Bleeding the Clutch System
71
(Inspection IV) Every 2 Years
71
Renewing Fuel Filter (Every 40,000 Km/24,000 Miles)
72
(Inspection III)
72
Removing/Installing Fuel-Pump Unit
72
Removing/Installing Fuel Filter
73
Removing/Installing Fuel Pump
74
Checking Coolant Level and Concentration; Topping up if Necessary; Checking Cooling System for Leaks if Necessary
75
(Inspections I and III)
75
Changing Coolant
76
Draining Coolant
76
Adding Coolant
77
Checking Battery
78
(Inspections III and IV)
78
Check Battery Acid Level and Add Distilled Water if Necessary; Inspect Battery Terminals and Clean and Grease Them if Necessary
78
Removing/Installing Battery
78
Adding Distilled Water
79
Replacing Intake Air Filter Element
79
(Inspection III)
79
Checking Function of Side-Stand Switch
80
(Inspections I, II and III)
80
Greasing Pivot of Side Stand, Checking Main (Centre) Stand
80
(Inspections II, III and IV)
80
Greasing the Side Stand Pivot
80
Checking the Centre Stand, Greasing It if Necessary
80
Checking the Centre Stand
80
Greasing the Centre Stand
80
Checking the Steering Damper
81
(Inspections II and III)
81
Checking Swinging Arm Bearings, Adjusting if Necessary
82
(Inspections I and III)
82
[Option Without BMW Integral ABS] Cleaning Inductive Signal Transmitter at Rear Wheel
82
Clean the Inductive Sensor at the Rear Wheel Every 40,000 Km (24,000 Miles) or Every 2 Years at the Latest
82
(Inspections III and IV)
82
Checking Tightness of Rear Wheel Studs
82
(Inspection I)
82
Checking Rear Wheel Bearing Play by Tilting Wheel
82
(Inspection III)
82
Checking Valve Clearances, Adjusting if Necessary
83
(Inspection III)
83
Checking Valve Clearances
83
Adjusting Valve Clearances
83
Replace the Lining of the Chain Tensioning Rail, Chain Guide Rail and Thrust Piece
85
(Every 60,000 Km/37,000 Miles)
85
Replacing Spark Plugs
86
(Inspection III)
86
Final Inspection with Road Safety and Functional Check
86
(Inspections I, II, III and IV)
86
11 Engine
87
Technical Data
91
Preparatory Work with Engine Installed
97
For Removal of Combined Oil/Water Pump
97
For Removal of Timing Case Cover, Removal of Timing Chain
97
For Removal of Cylinder Head, Removal of Piston with Conrod
97
For Removal of Crankshaft
97
For Removal of Intermediate Flange, Removal of Output Shaft
97
For Checking Valve Clearances, Adjusting Valve Clearances
97
Removing/Installing Engine
98
Removing Engine
98
Installing Engine
98
Disassembling Engine
99
Removing, Disassembling and Assembling Combined Oil-Water Pump
99
Removing the Oil/Water Pump
99
Disassembling the Oil/Water Pump
99
Removing Slipring Seal and Shaft Sealing Ring
99
Removing the Oil Pressure Relief Valve
99
Installing the Oil Pressure Relief Valve
99
Removing the Oil Pressure Switch and Regulating Element
100
Install the Pump Shaft with Shaft Sealing Ring and Slipring Seal
100
Installing Water Pump Impeller
100
Removing Timing Chain Cover
101
Remove the Crankcase Cover
101
Removing Ignition Trigger
101
Removing Cylinder Head Cover
101
Removing Timing Case Cover
102
Removing/Installing Shaft Sealing Ring in Timing Case Cover
103
Removing Shaft Sealing Ring from Timing Case Cover
103
Installing Shaft Sealing Ring in Timing Case Cover
103
Removing the Timing Chain
104
Removing Camshaft Chain Sprockets
104
Removing Chain Tensioner Rail
104
Removing Chain Guide Rail
104
Replace the Lining of the Chain Tensioning Rail and Thrust Piece
104
Removing, Disassembling and Assembling Cylinder Head
105
Removing Bucket-Type Tappets
105
Removing Cylinder Head
105
Removing Valves
105
Remachining Valve Seat
106
Installing Valve and Valve Stem Seal
106
Removing/Installing Coolant Sealing Cap at Top of Cylinder Head
107
Removing Crankshaft
108
Removing Big End Bearings
108
Removing Main Bearings (Engine Installed)
108
Removing Main Bearings (Engine Removed)
108
Removing, Disassembling and Assembling Piston with Conrod
109
Removing Piston with Conrod
109
Disassembling Piston
109
Checking Piston Dimensions
109
Assembling Pistons
110
Checking Cylinder Dimensions
110
Checking that Conrod Bores Are Parallel
110
Assembling Pistons and Conrods
111
Removing/Installing Crankshaft Gear and Rotor Flange
112
Measuring Backlash at the Countershaft
112
Removing Intermediate Flange
113
Removing Driver
113
Removing Intermediate Flange
114
Disassembling/Assembling Intermediate Flange
115
Removing the Driver Bearing
115
Installing Driver Bearing
115
Removing/Installing Shaft Sealing Ring for Driver
116
Removing Countershaft and Layshaft with Freewheel
116
Disassembling/Assembling Freewheel
117
Disassembling Freewheel
117
Assembling Freewheel
118
Removing/Installing Needle Bearings for Layshaft and Shaft Sealing Ring in Crankcase
118
Removing Bearing
118
Removing Shaft Sealing Ring
118
Installing Shaft Sealing Ring
118
Installing Bearing
118
Removing Output Shaft
119
Removing Oil Sump
119
Removing the Oil Mesh Strainer and Oil Filter
119
Removing Lower Part of Crankcase
119
Replacing Oil Level Sight Glass
119
Disassembling/Assembling Output Shaft
120
Disassembling Output Shaft
120
Disassembling Tensioning Gear
120
Assembling Tensioning Gear
121
Installing Dampers
122
Assembling Engine
122
Installing Output Shaft
122
Assembling the Crankcase
122
Installing Oil Mesh Strainer
123
Installing Oil Filter
123
Installing Oil Sump
123
Installing Intermediate Flange
124
Installing Freewheel
124
Installing Countershaft
124
Installing Output Shaft Sealing Ring
124
Installing Driver
125
Installing Crankshaft
125
Measuring Crankshaft Bearing Play
126
Measuring Radial Play
126
Measuring Endplay
126
Installing Piston with Conrod
127
Installing Big End Bearings
127
Measuring Big End Bearing Play
127
Checking Dimensions of Crankshaft
128
Installing Cylinder Head
129
Installing Camshafts
130
Installing Timing Chain
130
Installing Timing Case Cover
132
Checking Valve Clearances
132
Installing Ignition Trigger
133
Installing Ignition Trigger Cover
133
Installing Combined Oil/Water Pump
134
Installing Crankcase Cover
134
Installing Cylinder Head Cover
135
Checking/Adjusting Valve Clearances ( 00.74)
135
12 Engine Electrics
136
Technical Data
138
Renewing Hall-Effect Transmitter
140
Removing Cover from Hall-Effect Transmitter
140
Removing Magnetic Gate
140
Installing the Magnetic Gate
141
Installing the Cover of the Hall-Effect Transmitter
141
Replacing Spark Plugs/Ignition Leads
142
Removing/Installing Spark Plugs
142
Removing/Installing Ignition Leads
142
Timing the Ignition
143
Removing/Installing Coil
144
Replacing Three-Phase Generator
145
Removing Three-Phase Generator
145
Disassembling the Three-Phase Generator
146
Removing/Installing Drive Housing
146
Removing/Installing Voltage Regulator
146
Installing Generator
147
Replacing Starter Motor
148
Removing Starter Motor
148
Disassembling and Reassembling Starter Motor
149
Removing/Installing Brush Holder
149
Replacing Carbon Brushes
149
Installing Starter Motor
150
13 Fuel Preparation and Control
151
Technical Data
153
Removing/Installing Intake Air Filter ( a 00.70)
155
Removing/Installing Motronic Control Unit
155
Replacing Air Temperature Sensor
155
Removing/Installing Intake Air Silencer
156
Removing/Installing Fuel Injection Rail
157
Removing/Installing Injectors
158
Removing/Installing Pressure Regulator
158
Removing/Installing Throttle-Valve Rail
159
Removing/Installing Intake Stubs
160
Replacing Fuel Hoses
161
Removing/Installing Throttle-Valve Actuator
162
Basic Throttle Cable Setting ( a 00.36)
163
Preparatory Work for All Bowden Cables
164
Removing/Installing Throttle-Opener and Throttle-Closer Cables
164
[Cruise Control] Removing/Installing Throttle Cables
164
Removing/Installing Bowden Cable of Cruise-Control System
166
[Cruise Control] Removing/Installing Control Unit for Cruise Control
167
Checking Fuel Pressure
168
Troubleshooting
169
16 Fuel Tank and Lines
170
Technical Data
172
Removing/Installing Fuel Tank
174
Removing/Installing Fuel-Pump Unit
175
Removing/Installing Fuel Filter ( a 00.64)
176
Removing/Installing Fuel Pump
176
Removing/Installing Fuel Tank Vent
176
Removing/Installing Immersion-Tube Sensor
177
Calibrating the Immersion-Tube Sensor
177
Removing/Installing Fuel Filler Pipe
176
Renewing Front Left/Right Rubber Mounting
177
17 Radiator
178
Technical Data
180
Coolant Circuit
182
Removing/Installing Left Radiator
184
Removing/Installing Radiator with Fan
184
Removing/Installing Right Radiator
185
Removing the Right Fan
186
Removing/Installing Fan
186
Removing/Installing Left Fan
186
Removing/Installing Coolant Hoses
187
Changing Coolant ( a 00.67)
188
Check Cooling System for Leaks
188
Checking Thermostat
188
Removing/Installing Thermostat
188
Troubleshooting
189
Exhaust System
191
21 Clutch
197
Technical Data
199
Removing/Installing Clutch
201
Removing Clutch
201
Gearbox
201
Removing Clutch Housing
202
Installing Clutch Housing
203
Installing Clutch
204
Removing/Installing Clutch Slave Cylinder and Pushrod
205
Removing/Installing Clutch Slave Cylinder
205
Removing/Installing Clutch Pushrod
206
Removing/Installing Clutch Lines
207
Removing/Installing Clutch Pressure Line
207
Removing/Installing Bleed Line
208
23 Gearbox
209
Technical Data
211
Gearbox - Cutaway Drawing
213
Replacing the Shaft Sealing Rings in the Gearbox Housing and Gearbox Cover
215
Replacing Input Shaft Sealing Ring at Input End
215
Replacing Output Shaft Sealing Ring
215
Replacing Input Shaft Sealing Ring at Output Side
216
Replacing Shaft Sealing Ring for Selector Drum
216
Replacing Sealing Ring for Selector Shaft
216
Removing/Installing Gearbox
217
Removing Gearbox
217
Installing Gearbox
217
Disassembling Gearbox
219
Removing Gearbox Housing
219
Removing Selector Drum
220
Disassembling/Assembling Selector Shaft
220
Removing Gearbox Shafts
221
Renew the Grooved Ball Bearings for the Intermediate Shaft
221
Disassembling/Assembling Input Shaft
222
Disassembling Input Shaft
222
Assembling Input Shaft
223
Disassembling/Assembling Output Shaft
224
Assembling Output Shaft
224
Checking Endplay
227
Checking/Adjusting Fully Assembled Length of Selector Drum
227
Checking/Adjusting Fully-Assembled Length of Gearbox Shafts
228
Checking/Adjusting Fully-Assembled Length of Intermediate Shaft
228
Checking/Adjusting Fully-Assembled Length of Output Shaft
229
Assembling Gearbox
231
Installing Gearbox Shafts
231
Installing Input, Output and Intermediate Shafts
231
Shimming Selector Shaft
232
Installing Selector Shaft
232
Installing Selector Drum
233
Installing Gearbox Housing
234
Aligning Rubber Mounts
236
Aligning Left-Hand Rubber Mount
236
Aligning Right-Hand Rubber Mount
237
31 Front Forks
238
Technical Data
240
Removing/Installing Telescopic Fork
242
Removing Telescopic Fork
242
Installing Telescopic Fork
244
Removing/Installing Fork Bridge
246
Renewing Ball Joint
247
Removing/Installing Slider Tube Bridge
248
Removing/Installing Ball Joint
249
Disassembling/Reassembling Telescopic Fork
250
Disassembling Telescopic Fork
250
Assembling Telescopic Fork
251
Measuring Telescopic Fork
251
Check Slider Tube Bridge
251
Checking the Fixed Fork Tube for Runout
251
Removing/Installing Front Suspension Strut
252
Removing/Installing Steering Damper
254
Checking the Steering Damper
254
Removing/Installing Leading Link
255
Removing Leading Link
255
Installing Leading Link
256
Removing Left Leading Link Pivot Mount
257
Installing Left Leading Link Pivot Mount
257
Measuring the Leading Link
258
32 Steering
259
Technical Data
261
Removing/Installing Left Grip Tube
263
Removing/Installing Right Grip Tube
264
Removing/Installing Clutch Lever Fitting
265
Removing/Installing Brake Lever Fitting
266
Removing/Installing Left Handlebar Tube
267
Removing/Installing Right Handlebar Tube
268
Removing/Installing Left and Right Handlebar Levers
269
Removing/Installing Throttle Cables
269
33 Rear Wheel Drive
270
Rear Wheel Drive - Cutaway Drawing
274
Removing, Disassembling, Reassembling and Installing Rear Wheel Drive
276
Removing Rear Wheel Drive
276
Replacing Taper Roller Bearing in Rear Wheel Drive
276
Removing Input Bevel Pinion
277
Disassembling Input Bevel Pinion
279
Assembling Input Bevel Pinion
280
Installing Input Bevel Pinion
281
Removing Crown Wheel
283
Installing Crown Wheel
284
Checking/Adjusting Backlash
285
Checking Tooth Contact Pattern
286
Shimming Housing Cover
287
Installing Housing Cover
287
Installing Rear Drive Shaft
288
Installing Rear Wheel Drive
288
Removing, Disassembling, Reassembling and Installing Rear Swinging Arm
290
Removing Rear Swinging Arm
290
Removing/Installing Flexible Gaiter
291
Removing/Installing Threaded Ring Bearings
291
Removing Drive Shaft
292
Checking Universal Joint for Wear
292
Installing Drive Shaft
292
34 Brake
295
Technical Data
297
[Integral ABS] Removing/Installing Rear Brake Caliper
299
[Integral ABS] Removing/Installing Front Brake Caliper
299
Disassembling and Assembling Front Brake Caliper
300
Disassembling and Assembling Rear Brake Caliper
301
Disassembling Rear Brake Caliper
301
Assembling Rear Brake Caliper
301
[Integral ABS] Removing/Installing Rear Brake Disc
302
[Integral ABS] Removing/Installing Front Brake Disc
302
[Integral ABS] Removing/Installing Front ABS Sensor Ring
303
[Integral ABS] Removing/Installing Front ABS Sensor
303
[Integral ABS] Removing/Installing Rear ABS Sensor
304
[Integral ABS] Marking Rear ABS Sensor Ring
305
[Integral ABS] Checking and Adjusting Rear ABS Sensor
305
Checking ABS Sensor Gap
305
Adjust ABS Sensor Gap
305
[Integral ABS] Removing/Installing Rear Master Brake Cylinder
306
[Integral ABS] Checking/Adjusting the Blow-By Clearance of the Piston Rod
306
Checking Blow-By Clearance at Piston Rod
306
Adjusting Blow-By Clearance at Piston Rod
306
[Integral ABS] Removing/Installing Pressure Modulator
307
Disassembling Pressure Modulator, Removing/Installing Brake Lines
309
[Integral ABS] Draining Brake System
310
[Integral ABS] Draining Wheel Circuit
310
Draining Rear Wheel Circuit
310
Draining Front Wheel Circuit
310
[Integral ABS] Draining Control Circuit
310
Bleeding Rear Control Circuit
310
Bleeding Front Control Circuit
310
[Integral ABS] Filling Brake System
311
[Integral ABS] Filling the Wheel Circuit
311
Filling the Front Wheel Circuit
311
Filling Rear Wheel Circuit
312
[Integral ABS] Filling Control Circuit
313
Filling the Front Control Circuit
313
Bleeding Front Control Circuit ( a 00.52)
313
Filling the Rear Control Circuit
314
Bleeding Rear Control Circuit ( a 00.55)
314
[Integral ABS] Wheel Circuit, Only Bleeding
315
Preliminary Work - Bleeding Front Wheel Circuit
315
Front Wheel Circuit Only Bleeding
315
Rear Wheel Circuit Only Bleeding
317
[Integral ABS] Performing Bleed Test with BMW Moditec ( 00.35)
318
[Integral ABS] Removing Front Brake Lines/Hoses
319
Preparatory Work
319
[Integral ABS] Removing/Installing Rear Brake Lines/Hoses
321
[Integral ABS] Removing Brake Lines/Hoses
321
Preparatory Work
321
[Integral ABS] Installing Rear Brake Lines/Hoses
321
Removing/Installing Hose with Cap of Wheel Circuit Reservoir
323
[Integral ABS] Checking Brake Pads for Wear/Replacing ( 00.41)
323
[Integralabs] Checking Brake Fluid Level at Handlebar Fitting ( 00.43)
323
36 Wheels and Tyres
324
Technical Data
326
Removing/Installing Front Wheel
328
Removing/Installing Wheel Bearings
329
Removing Left/Right Wheel Bearings
329
Installing Right/Left Wheel Bearing
330
Installing Left Wheel Bearing
330
Installing Right Wheel Bearing
330
Removing/Installing Rear Wheel
331
Removing Rear Wheel
331
Installing Rear Wheel
331
Static Balancing of Front and Rear Wheels
332
Static Balancing of Front Wheel
332
Static Balancing of Rear Wheel
332
Checking Front/Rear Wheel Rim for Runout
333
Checking Front Wheel Rim for Runout
333
Checking Rear Wheel Rim for Run-Out
334
46 Frame
335
Technical Data
337
General View of Body Panels
339
Removing/Installing Mudguards
340
Removing/Installing Front Mudguard
340
Removing/Installing Tail Section
341
Removing/Installing Rear Carrier Section
341
Removing/Installing Fairing Side Section
342
Removing/Installing Left/Right Inner Trim
342
Removing/Installing Upper Section of Fairing
343
Removing Left and Right Fairing Side Sections
344
Removing/Installing Windscreen
345
Removing/Installing Cover for Windscreen Holder
346
Removing/Installing Windscreen Holder
346
Removing/Installing Instrument-Panel Trim
347
Removing/Installing Engine Spoiler
348
Removing/Installing Bracket for Engine Spoiler
348
Removing/Installing Left/Right Tail Side Section
349
Removing/Installing Intake Air Pipe
351
Removing/Installing Air Guide
351
Removing/Installing Discharge Air Guide for Left/Right Radiators
352
Removing/Installing Heat Shield
352
Removing/Installing Lock Carrier
353
Removing/Installing Main Stand/Side Stand
354
Removing/Installing Pivot Mount with Centre (Main) and Side Stands
354
Removing/Installing Main (Centre) Stand
354
Removing/Installing Footrest System
355
Removing/Installing Right Footrest System
355
Removing/Installing Brake Pedal
355
Removing/Installing Footrest
355
Removing/Installing Left Footrest System
356
Adjusting Left/Right Footrests
356
Adjusting Gear Shift Lever
356
Removing/Installing Rear Left Footrest Holder
357
Removing/Installing Rear Right Footrest Holder
357
Removing/Installing Rear Frame
358
Removing/Installing Frame
359
Removing/Installing Cross-Tube
359
Removing/Installing Left/Right Cross-Member
359
Removing/Installing Frame
360
Lifting Frame
363
Lowering the Frame
365
Supporting the Frame
368
Removing/Installing Right and Left Threaded Bushes for Swinging-Arm Pivot
368
Removing Threaded Bushes
368
Installing Threaded Bushes
369
Measuring Wheel Track Offset
370
51 Equipment
372
Removing/Installing Ignition Switch/Steering Lock
374
Removing/Installing Lock Barrel
374
Removing/Installing Fuel Tank Lock Barrel
375
Removing/Installing Mirror ( a 00.22)
376
Removing/Installing Seat Lock
376
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BMW K 1200RS Repair Manual (386 pages)
Brand:
BMW
| Category:
Motorcycle
| Size: 38.01 MB
Table of Contents
Usage
4
Key to Symbols
4
Contents
5
Tightening Torques
12
Table of Operating Fluids
21
Maintenance Intervals
22
Changing Engine Oil, Renewing Oil Filter Element
23
Gearbox Oil Change
24
Rear Wheel Drive Oil Change
24
Checking Valve Clearances, Adjusting if Necessary
25
Renewing Spark Plugs
27
Renewing Fuel Filter
28
Removing the Fuel Pump Unit
28
Removing and Installing Fuel Filter
29
Removing/Installing Fuel Pump
29
Installing Fuel Pump Unit
29
Checking Hose Unions
30
Renewing Coolant
31
Draining Coolant
31
Adding Coolant
31
Battery Removal and Installation
32
Topping up with Distilled Water (Battery)
32
Renewing Intake Air Cleaner
33
Brake System
33
Brake Pads/Brake Discs
34
Renewing Brake Pads
35
Checking Brake Fluid Level/Topping up
36
Renewing Brake Fluid and Bleeding Brake System
37
Additional Preliminary Work
38
Rear Brake
39
Bleeding the Brakes
41
Checking Operation of Side (Prop) Stand Switch
43
Greasing the Side (Prop) Stand
43
Checking Main (Centre) Stand, Greasing if Necessary
43
Lubricating Main (Centre) Stand
44
Checking Clutch Fluid Level, Correcting if Necessary
45
Checking Tightness of Rear Wheel Studs
45
Cleaning the Inductive Sensor at the Rear Wheel
45
Reading out Moditec Fault Memory
46
Checking Throttl Cable Play, Adjusting if Necessary
46
Final Inspection with Road Safety and Functional Check
46
Engine
48
Engine Technical Data
52
Preparatory Work with Engine Installed
58
Removing Engine
58
Dismantling Engine
59
Removing Timing Chain Cover
61
Removing the Timing Chain
63
Removing, Stripping down and Assembling Cylinder Head
64
Removing Crankshaft
66
Removing Piston with Conrods, Stripping down and Re-Assembling
67
Checking Cylinder Dimensions
68
Removing and Installing Crankshaft Sprocket and Rotor Flange
69
Removing Intermediate Flange
69
Stripping down and Re-Assembling Intermediate Flange
71
Removing Countershaft and Layshaft with Freewheel
72
Dismantling and Assembling Freewheel
73
Removing Output Shaft
75
Stripping and Assembling Output Shaft
76
Installing Output Shaft
78
Installing Intermediate Flange
80
Measuring Crankshaft Bearing Play
81
Checking Dimensions of Crankshaft
82
Installing Piston with Controd
82
Installing Bid End Bearing
83
Measuring Big End Bearing Play
83
Installing Cylinder Head
84
Installing Camshafts
85
Installing Timing Chain
86
Installing Timing Case Cover
88
Installing Ignition Transmitter
89
Installing Ignition Transmitter Cover
89
Installing Combined Oil/Water Pump
90
Installing Crankcase Cover
90
Installing Cylinder Head Cover
91
Installing Engine
91
Checking/Adjusting Valve Clearances
92
Engine Electrical System
95
Engine Electrical System Technical Data
97
Renewing Hall-Effect Transmitter
99
Installing the Magnetic Gate
100
Install the Cover of the Hall-Effect Transmitter
100
Removing Spark Plugs/Ignition Leads
101
Timing the Ignition
102
Removing/Installing Coils
103
Renewing Alternator
104
Stripping down Alternator
105
Installing Alternator
106
Renewing Starter Motor
107
Removing Starter Motor
107
Stripping and Re-Assembling Starter Motor
108
Installing Starter Motor
109
Fuel Tank and Lines
111
Fuel Tank and Lines Technical Data
113
Removing and Installing Fuel Tank
115
Removing/Installing Fuel Pump Assembly, Fuel Filter and Fuel Pump
116
Removing/Installing Fuel Filler Pipe
117
Removing/Installing Fuel Tank Vent
117
Removing/Installing Immersed Level Sensor
118
Renewing Front Left/Right Rubber Mounting
118
Fuel Preparation and Control
120
Fuel Data
122
Removing and Installing Air Cleaner Element
124
Renewing Air Temperature Sensor
124
Removing and Installing Intake Air Silencer
125
Removing and Installing Fuel Injection Rail
126
Removing and Installing Injectors
127
Removing and Installing Pressure Regulator
127
Removing and Installing Throttle Rail
128
Removing and Installing the Intake Pipe
129
Renewing Fuel Hoses
130
Removing and Installing Throttle Positioner
131
Exchanging and Adjusting the Throttle Potentiometer
132
Basic Throttle Cable Setting
132
Removing and Installing Motronic Control Unit
133
Checking Fuel Pressure
134
Cooling
137
Cooling System Technical Data
139
Coolant Circuit Diagram
141
Draining and Adding Coolant
143
Removing and Installing Radiator with Fan
144
Removing and Installing Fan
146
Removing and Installing Coolant Hoses
147
Removing and Installing Thermostat
148
Checking Cooling System for Leaks
148
Cooling System Troubleshooting
149
Exhaust System
152
Exhaust System Technical Data
154
Removing and Installing the Exhaust System
156
Removing and Installing the Exhaust System Sleeve
157
Clutch
159
Clutch Technical Data
161
Removing and Installing Clutch
163
Removing Clutch Housing
164
Installing Clutch Housing
165
Installing Clutch
166
Removing/Installing Clutch Slave Cylinder and Clutch Release Rod
167
Removing/Installing Clutch Release Rod
168
Removing/Installing Clutch Lines
169
Gearbox
172
Gearbox Technical Data
174
Gearbox Sectional Drawing
176
Removing Gearbox
178
Dismantling Gearbox
180
Removing Gearbox Housing
180
Removing Selector Drum
181
Dismantling/Assembling Selector Shaft
181
Removing Gearbox Shafts
182
Dismantling/Assembling Input Shaft
183
Dismantling/Reassembling Output Shaft
185
Checking Endplay
187
Renewing the Shaft Sealing Rings
188
Checking/Adjusting Fully-Compressed Length of Selector Drum
189
Checking/Adjusting Fully-Compressed Lengths of Gearbox Shafts
190
Rassembling Gearbox
193
Installing Gearbox Shafts
193
Installing Selector Drum
195
Installing Gearbox Housing
196
Installing Gearbox
198
Front Fork
201
Front Fork Technical Data
203
Removing Telescopic Fork
205
Installing Telescopic Fork
207
Removing and Installing Fork Bridge
209
Removing and Installing Slider Tube Bridge
211
Dismantling Telescopic Fork
213
Measuring Telescopic Fork
214
Assembling Telescopic Fork
214
Removing and Installing Front Suspension Strut
215
Removing/Installing Steering Damper
217
Checking the Steering Damper
217
Removing Leading Link
218
Installing Leading Link
219
Removing and Installing Leading Link Pivot Mount
220
Measuring the Leading Link
221
Steering
223
Steering Technical Data
225
Removing/Installing Left Grip Tube
227
Removing/Installing Right Grip Tube
228
Removing/Installing Clutch Lever Fitting
229
Removing/Installing Brake Lever Fitting
230
Removing/Installing Left Handlebar Tube
231
Removing/Installing Right Handlebar Tube
232
Removing/Installing Throttle Cable
233
Removing/Installing Left and Right Handlebar Levers
234
Renewing Brake Fluid for Clutch Operation
235
Bleeding Clutch Operating System
235
Renewing Brake Fluid / Bleeding Brake System
236
Rear Wheel Drive
238
Rear Wheel Drive Technical Data
240
Rear Wheel Drive - Sectional Drawing
242
Removing, Dismantling, Reassembling and Installing Rear Wheel Drive
243
Removing Crown Wheel
250
Installing Crown Wheel
251
Checking Tooth Contact Pattern
253
Shimming Housing Cover
254
Installing Housing Cover
254
Installing Rear Drive Shaft
254
Installing Rear Wheel Drive
255
Removing Rear Swinging Arm
256
Removing and Installing Flexible Gaiter
257
Removing/Installing Threaded Ring Bearings
257
Removing Drive Shaft
258
Installing Drive Shaft
258
Installing Rear Swinging Arm
259
Removing and Installing Suspension Strut
260
Brakes
262
Brakes Technical Data
264
Removing and Installing Front Brake Caliper
266
Removing and Installing Rear Brake Caliper
267
Removing and Installing Front Brake Disc
268
Removing/Installing Rear Brake Disc
268
Removing and Installing Front ABS Sensor
269
Adjusting Front ABS Sensor
270
Removing and Installing Rear ABS Sensor
271
Adjusting Rear ABS Sensor
272
Removing and Installing Rear Brake Master Cylinder
274
Checking/Adjusting Blow-By Clearance at Piston Rod
274
Removing/Installing ABS Control Unit
275
Removing/Installing ABS Relay
277
Removing/Installing Front Brake Lines/Hoses
279
Removing/Installing Rear Brake Lines/Hoses
281
Checking Brake Pads and Discs for Wear/Renewing
283
Checking Brake Fluid Level/Tipping up
285
Bleeding the Brake System
290
Wheels and Tyres
293
Wheels and Tyres Technical Data
295
Removing and Installing Front Wheel
297
Removing and Installing Wheel Bearings
298
Removing/Installing Rear Wheel
300
Static Balancing of Front and Rear Wheels
301
Checking Front/Rear Wheel Rim for Runout
302
Frame
305
Frame Technical Data
307
General View of Fairing Sections
309
Removing Dualseat
310
Installing Dualseat
310
Adjusting Dualseat
310
Removing/Installing Front Mudguard
311
Removing/Installing Rear Section
312
Removing/Installing Rear Carrier Section
312
Removing/Installing Fairing
313
Removing/Installing Intake Air Guide
315
Removing/Installing Air Outlet Guide for Left/Right Radiator
316
Removing/Installing Engine Spoiler
316
Removing/Installing Holder for Engine Spoiler
317
Removing/Installing Left/Right Rear Side Section
317
Removing/Installing Left/Right Inner Cover
318
Removing/Installing Windshield and Windshield Holder
319
Removing/Installing Upper Section of Fairing with Headlight
320
Removing and Installing Fairing Holder
321
Removing/Installing Heat Shield
322
Removing/Installing Grab Handle
322
[OE] Removing/Installing Pannier Case Carrier
322
[OE] Removing/Installing Luggage Rack
322
Removing/Istalling Lock Carrier
323
Stripping/Assembling Side (Prop) Stand
323
Removing/Insgalling Pivot Mount with Centre (Main)
323
Stripping/Assembling Centre (Main) Stand
324
Removing/Installing Footrest Supports
325
Adjusting Footrests at Left/Right
327
Removing and Installing Frame
328
Removing/Installing Cross-Tube
329
Removing/Installing Left/Right Cross-Member
329
Measuring Wheel Track Offset
333
Equipment
336
Raise the Frame
338
Lowering the Frame
341
Removing/Installing Ignition Switch/Steering Lock
345
Removing and Installing Fuel Tank Lock Barrel
346
Removing and Installing Dualseat Lock
347
General Electrical System
349
Electrical - Technical Data
351
Removing/Installing Battery
353
Removing/Installing Electronic Equipment Box
354
Wiring Harness
355
Relay Positions in Electronic Equipment Box
357
Renewing Left Combined Switch and Clutch Switch
358
Renewing Right Combined Switch and Brake Switch
360
Removing/Installing Fuse Box
362
Removing/Installing Inductive Sensor for Speedometer
363
Renewing ABS Sensor at Front/Rear
363
Removing/Installing Water Temperature Sensor
363
Renewing Side (Prop) Stand Switch
364
Renewing/Adjusting Foot Brake Light Switch
365
Removing/Installing Ignition Switch/Steering Lock Cable
366
Removing/Installing Oil Pressure Switch for Temp. Sensor at Water Pump
367
Removing/Installing Horn
368
Removing/Installing Gear Indicator
368
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