BMW K 1200RS Operating instructions

BMW Motorrad
After Sales
K 1200 RS
Repair Manual

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

Introduction
This Repair Manual will help you to perform all the main maintenance and repair work correctly and effi-
ciently. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and
practical knowledge acquired at the BMW Training Centre. It is a contribution towards achieving even high-
er Service quality.
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.
•The Repair Manual is structured in the logical sequence of the work to be performed: Removal, Disas-
sembly, Repair, Assembly, Installation.
•The entire contents are divided into individual chapters, corresponding to the Construction Groups.
11 . 10
Chapter Page number within chapter
If a reference is needed to a different page or chapter, an arrow symbol is shown followed by the chapter
and page numbers, e.g. (a 12.5)
•Work to be performed during an Inspection is described in Group “00”. The various inspection routines
are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that
work can take place without interruption.
•Use of the BMW special tools needed for certain tasks is described in the work instructions.
If the need arises, repair instructions are also issued in the form of Service Information. This information is of
course incorporated into the next issue of the Repair Manual. We also recommend, as an additional source
of information, the Electronic Parts Catalogue (EPC), which contains clear and easy-to-follow illustrations.
If the work described here is restricted to a particular equipment specification, for instance if a specific
optional extra (Option) is fitted, this is stated in square brackets at the start of the item concerned, e.g.
[Heated handlebar grips].
Please refer to the following pages as well for a description of other symbols used and how to work with them.
BMW Motorrad
After Sales
Issued by BMW Motorrad
After Sales
UX-VS-2
D-80788 München
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.
Produced in Germany

Use
Each chapter starts with the list of contents.
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
LNote:
Specific information on operating, inspecting and adjusting work for the motorcycle as well as maintenance
procedures.
eImportant:
Instructions and precautions specifically intended to prevent damage to the motorcycle. Failure to comply
with them could invalidate the warranty.
dWarning:
This symbol stands for precautions and measures which are essential in order to protect the rider or other
persons from possibly severe or fatal injury.
Contents
The titles of the tasks described in this chapter............. complete with page numbers
Activities
•Activities
•The bullet symbol means that work steps are described in greater detail under another headline
–Preceding activities
–A line indicates work steps described in greater detail under another headline or in another chapter
If the term “undo”or “remove”is used:
the fastener (e.g. screw) must be slackened off and taken out
or
a component (e.g. fuel rail) must be removed to the extent that other components which it conceals (e.g.
throttle valve rail) are accessible
If the term “loosen”or “slacken”is used
the fastener (e.g. screw) must only be slackened off but not taken out
XTightening torques:
Values are stated if they differ from DIN EN 24 014 or DIN 912 ISO industrial standards.

Order No. 01 71 0 138 275 UX-VS-2, 02.2001 2nd edition Printed in Germany
Customer Licence plate No.
Order No. Mechanic’s signature
BMW Inspection at 1,000 km (600 miles) BMW Service 10,000 km (6,000 miles) BMW Inspection every 20,000 km (12,000 miles) BMW Annual Service
Read out the fault memory with the 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
done every 3 months or at least every 3,000 km (1,800 miles) *)
Change oil in gearbox while at operating temperature
at least every 2 years *)2
Change oil in rear wheel drive while at operating temperature,
Every 40,000 km (24,000 miles), Every 2 years at the latest *) 40,000 2
Examine brake pads and discs for wear, replace if necessary *)
Check operation of brake system and freedom from leaks; repair/replace items if necessary *)
[Integral ABS] Checking brake fluid level at handgrip
[Integral ABS] change bake fluid in wheel circuit at least every 12 months
[Integral ABS] change brake fluid in control circuit at least every 2 years *)
2
[Integral ABS] perform bleed test with BMW MoDiTeC
[OE, without Integral ABS] Check the front/rear brake fluid level
[OE, without Integral ABS] Change the brake fluid at least once a year
Check clutch operating fluid level
Change clutch fluid
every 2 years at the latest *) 2
Replace fuel filter *)
generally every 40,000 km (24,000 miles), if the fuel is of poor quality, every 20,000 km (12,000 miles)
40 000
Check coolant level and concentration, top up if necessary and check cooling system for leaks
Replace the coolant at least every 2 years*)
2
Check battery acid level, if necessary add distilled water
Clean/grease battery terminals if necessary
Replace intake air cleaner element
If severe dirt and dust are encountered, replace the intake air cleaner every 10,000 km (6,000 miles) or even more
frequently *)
Check function of side stand contact switch
Grease side stand bearing, check that the centre stand moves freely, and grease it if necessary *)
Check the steering damper
Check tightness of rear wheel studs
Check rear wheel bearing play by rocking wheel
Check swinging arm bearings (free of play), adjust if necessary *)
[OE, without Integral ABS] Clean the inductive sensor on the rear wheel
Every 40,000 km (24,000 miles) or at the latest every 2 years *) 40 000 every
2years
Check valve clearances, adjust if necessary *)
Replace the lining of the chain tensioning rail, chain guide rail and thrust piece every 60,000 km
(36,000 miles)*)60 000
Replace spark plugs
Final inspection with road safety and functional check:
–Condition of tires and wheels, tyre pressure
–Clutch, gearshift mechanism, hand and foot brake, Integral ABS, steering system
–Lights and signalling equipment, telltale and warning lights, instruments, horn
–Optional equipment and accessories fitted
–Trial run if necessary
*) Charged as an additional item
BMW Motorrad
Maintenance schedule
K 1200 RS as of model year 01, Integral ABS

Order No. 01 71 0 138 275 UX-VS-2, 02.2001 2nd edition Printed in Germany
Customer Licence plate No.
Order No. Mechanic’s signature
BMW
Pre-delivery check
Check the shipping crate for damage
Unpacking the motorcycle
–unpack
–inspect for damage
–check that delivery is complete: Motorcycle keys
Toolkit and documentation
Optional extras
Installing remaining items on motorcycle
–Fit the mirror, engine spoiler
–Install the windshield
Fill and charge the battery (mark with charging date)
Check tyre pressures
Check rear wheel studs for tightness (note correct tightening torque!)
Checking and adjusting the motorcycle
–Check function of side stand contact switch
–Headlight, Seat
–Spring strut
–Handlebars, footrest system, gearshift lever
[Integral ABS] perform bleed test with BMW MoDiTeC
Add fuel
Final inspection and function check
–Check engine oil when engine is cold
–Clutch, gearshift mechanism
–Lights and signalling equipment, telltale and warning lights, instruments
–Hand brake and foot brake
–Check optional equipment for operation
–Trial run if necessary
Confirm pre-delivery check in Service and Technical Booklet
Final cleaning
Motorcycle handed over on:
BMW Motorrad
Pre-delivery check
K 1200 RS as of model year 01, Integral ABS

Order No. 01 71 0 139 086 UX-VS-2, 01/01 Printed in Germany
Item Desired value Unit of measure-
ment
Oil capacities
Engine (with filter)
Gearbox
Top up the oil to the bottom of the filler opening
Rear wheel drive
3.5 (6.2)
Initial filling about 0.6 (1.0)
Initial filling 0.25 (0.44)
Oil changes 0.23 (0.40)
litres (Imp. pints)
litres (Imp. pints)
litres (Imp. pints)
litres (Imp. pints)
Coolant
50% water/50% nitrite free antifreeze
In expansion tank
Test pressure for cooling system (min. 5 minutes)
2.5 (4.40)
+ 0.6 (+ 1.0)
1.5 (21.76)
litres (Imp. pints)
litres (Imp. pints)
bar (psi)
Valve clearances
Measured cold (max. 35 °C) I: 0.15…0.20 (0.0059...0.0079)
E: 0.25…0.30 mm
(0.0098...0.0118)
mm (in)
mm (in)
Ignition timing
Adjustment with MoDiTeC
Setting static / corresponds to 6 / 0.24(0.01) - 1 cylinder °/ mm (in) before TDC
Spark plugs Bosch XR 7 LDC
Idle speed 1,050 rpm
Brakes DOT 4 brake fluid
Colour of identification mark on brake calipers/
brake pads, front
Minimum lining thickness front/rear
Minimum brake disc thickness, front/rear
white
1 (0.0394)
4.5 (0.1772) mm (in)
mm (in)
Lubricant for centre stand/side stand Shell Retinax EP2
Tyre pressures One-up/two-up/luggage front: rear:
2.5 2.9
(36.26 –42.061)
bar (psi)
bar (psi)
Throttle cable play warm engine
without cruise control
[OE, without Integral ABS]
with cruise control
Cruise control cable
0.5 (0.02)
1...1.5 (0.04...0.06)
2...3 (0.08...0.12)
mm (in)
mm (in) on throttle twist grip
mm (in)
Tightening torques:
Oil filter
Oil filter cover
Engine oil drain plug
11
10
30
Nm
Nm
Nm
Gearbox oil drain plug
Gearbox oil filler plug 55 30 Nm Nm
Oil drain plug/filler plug rear wheel drive 23 Nm
Cylinder head cover
(Cylinder head sealing surface edges/half-moon sections)
Spark plugs
Camshaft bearing cap to cylinder head
Screw plug for chain tensioner
Sprocket to camshaft
Timing chaincase cover to crankcase
Cylinder head screws (oiled for installation)
tightening angle
9
(Three Bond 1209)
20
10
9
56
9
20
90
Nm
Nm
Nm
Nm
Nm
Nm
Nm
°tightening angle
Pump unit to fuel tank
Fuel tank at rear, to frame, M8 30 21 Nm Nm
Coolant expansion tank to frame 6Nm
Battery tray to battery holder 4Nm
Brake caliper fasteners front/rear
Brake bleed screw, front/rear
Filling adapter grub screw
30/40
7/10
10
Nm
Nm
Nm
Centre stand to pivot point 41(Loctite 243) Nm (clean thread)
Quick-release axle, front wheel
Pinch bolt, quick-release axle 30 21 Nm Nm
Rear wheel studs (initial torque 50 Nm) 105 Nm
[OE, without Integral ABS] Speed sensor mount 4Nm
Swinging arm to frame left/right bearing studs
Threaded ring, left/right
Counter-ring, left
160
10/200
160
Nm
Nm
Nm
Spring strut to swinging arm
Spring strut to frame 50 43 Nm Nm
BMW Motorrad
Service data
K 1200 RS as of model year 01, Integral ABS

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
>> Continuation
Contents
<< Back
Group / Chapter

>> 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

00.1
Contents Page
00
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
32 Steering ........................................................................................................................................9
33 Rear wheel drive .......................................................................................................................9
34 Brakes [Integral ABS] ...........................................................................................................10
34 Brakes [Optional extras, without Integral ABS] ......................................................... 11
36 Wheels and tyres .................................................................................................................... 11
46 Frame ..........................................................................................................................................12
51 Equipment .................................................................................................................................13
61 General electrical equipment ............................................................................................14
62 Instruments ...............................................................................................................................14
63 Lights ...........................................................................................................................................14
Table of operating fluids .........................................................................................................15
00 Tightening torques,
operating fluids

00.2
Contents Page

00.3
00
Tightening torques
Model K 1200 RS
Connection
11 Engine
Cylinder head
Cylinder head bolts Nm 20 Oiled before installation
Wrench angle °90
Cylinder head cover Nm 9
Temperature sensor Nm 30
Coolant stub pipe Nm 9
Shield plate Nm 9
Split conrods
Split-conrod bearing cap Nm 20
Wrench angle °80
Engine block
Shouldered bearing Nm 40
Needle roller bearing Nm 18
Lower part of crankcase Nm 10
Oil mesh strainer Nm 10
Oil filter Nm 11
Oil sump Nm 10
Oil filter cover Nm 10
Oil drain plug Nm 30
Freewheel
Cover plate Nm 10
Intermediate flange
Thrust plate to intermediate flange Nm 9 Clean thread + Loctite 243
Intermediate flange to crankcase Nm 9
Driver to auxiliary shaft Nm 50
Crankshaft
Rotor flange to crankshaft Nm 50
Main bearings Nm 50
Crankcase cover Nm 9
Camshaft
Bearing cap Nm 10
Chain sprockets Nm 56

00.4
Timing chain
Slider rail to camshaft bearing cap Nm 9
Timing case cover
Chain tensioner to cover of timing case Nm 9
Screw plug for chain tensioner Nm 9
Timing case cover Nm 9
Oil/water pump
Oil pressure switch
to oil pump intermediate flange Nm 35
Water pump temperature sensor Nm 9
Screw plug, M 12 Nm 20
Oil pressure relief valve screw plug Nm 35
Water-pump impeller to pump shaft Nm 33
Pump housing to crankcase Nm 10
Pump housing cover Nm 10
Oil cooler
Oil lines to oil cooler Nm 25
Model K 1200 RS
Connection
12 Engine electrics
Spark plugs Nm 20
Ignition coil Nm 9
Ignition trigger
Rotor Nm 4
Magnetic gate Nm 6
Ignition trigger cover Nm 9
Alternator
Alternator to intermediate flange, M8 Nm 21
Driver Nm 50
Nut to alternator D+ M5 Nm 10
Nut to alternator B+ M8 Nm 10
Model K 1200 RS
Connection
11 Engine

00.5
Starter motor
Starter motor to gearbox, M6 Nm 20
Positive lead to starter motor, M6 Nm 15
Earth (ground) lead to cross-tube Nm 6
Model K 1200 RS
Connection
13 Fuel preparation and control
Temperature sensor to intake air silencer Nm 15
Hose clips to throttle stub pipe Nm hand-tight
Screw for fuel injection rail to engine block Nm 9
Hose clips for fuel line Nm hand-tight
Hose clip at intake stub pipe Nm hand-tight
Intake stub pipe Nm 9
Retaining clip (fastener clips) to engine Nm 9
Screws, throttle-valve actuator Nm 5 Clean thread + Loctite 243
Screws, throttle-valve potentiometer Nm 2 Clean thread + Loctite 243
Model K 1200 RS
Connection
16 Fuel tank and lines
Rubber mounts to frame Nm 22
Fuel tank to frame Nm 22
Fuel pump unit to fuel tank Nm 30
Immersed fuel level sensor to fuel tank, M5 Nm 5
Filler pipe to fuel tank Nm 5
Model K 1200 RS
Connection
12 Engine electrics

00.6
Model K 1200 RS
Connection
17 Radiator
Expansion tank to frame Nm 6
Fan to radiator Nm 2 Clean thread + Loctite 243
Coolant hose clips Nm hand-tight
Model K 1200 RS
Connection
18 Exhaust system
Exhaust system to cylinder head Nm 22
Retaining hoop to silencer (muffler) Nm 15
Retaining hoop to frame Nm 20
Oxygen sensor to silencer Nm 45 Apply Optimoly TA to thread
Retaining plate to silencer (muffler) Nm 20
Retaining hoop to holder Nm 13
Cover Nm 8
Model K 1200 RS
Connection
21 Clutch
Clutch housing to output shaft
Tighten to Nm 140
Slacken off
Tighten to Nm 50
Wrench angle °60
Housing cover to clutch housing Nm 12
Slave cylinder to gearbox Nm 9
Banjo bolts to slave cylinder Nm 7
Filler adapter
Grub screw in filler adapter Nm 10
Handlebar fitting
Clutch line/banjo bolt Nm 18

00.7
Model K 1200 RS
Connection
23 Transmission
Housing
Oil drain plug Nm 55
Oil filler plug Nm 23
Housing cover to housing Nm 9
Gearshift linkage
Selector lever to selector shaft Nm 9
Gearshift pedal to transverse tube
pivot bushing Nm 8 Staburags NBU 30 PTM
Gearshift lever, M6, adjustable Nm 8
Ball end to gearshift lever/
shift lever
Ball head
Nm 5
Clean thread + Loctite 243
Staburags NBU 30 PTM
Gearbox mounts
Gearbox to frame Nm 70
Gearbox to intermediate flange Nm 22
Clamp, rubber mount
Do not release left rubber mount (TORX) Nm 9

00.8
Model K 1200 RS
Connection
31 Front fork
Fork leg
Oil drain plug, sliding tube Nm 13
Screw plug in fixed tube Nm 20
Leading link
Leading link to sliding tube bridge Nm 130 Clean thread and Loctite 2701
Leading link to frame Nm 107 Clean thread and Loctite 243
Clamp, leading link M8 Nm 21
Steering damper to leading link, M8 Nm 21 Clean thread and Loctite 243
Handlebars / fork bridge
Handlebars, left/right to handlebar holders Nm 20
Handlebar holder clamp Nm 21 Clean thread and Loctite 243
Handlebar holder to fork bridge Nm 9
Fork bridge clamp Nm 21
Fork bridge to frame
(nut micro-encapsulated) Nm 130 Clean thread and Loctite 2701
Ball joint to fork bridge Nm 230 Lightly grease threads with Optimoly TA
Sliding tube bridge
Sliding tube bridge to sliding tube, M8 Nm 21 Clean thread and Loctite 243
Steering damper to sliding tube bridge, M8 Nm 21 Clean thread and Loctite 243
Ball joint to sliding tube bridge Nm 230 Lightly grease threads with Optimoly TA
Spring strut
Spring strut to frame, M10 Nm 43
Spring strut to leading link, M10 Nm 43

00.9
Model K 1200 RS
Connection
32 Steering
Fastener for brake lever fitting Nm 6
Fastener for clutch lever fitting Nm 6
Cover for cable guide Nm 7
Pivot screw, handlebar lever Nm Clean thread and Loctite 243
Model K 1200 RS
Connection
33 Rear wheel drive
Rear wheel drive
Housing cover to housing Nm 35
Threaded ring Nm 118 Clean thread and Loctite 577
Nut for input bevel pinion Nm 200 Clean thread and Loctite 2701
Oil filler/drain plug Nm 23
Rear wheel drive to swinging arm
Fixed bearing stud bolt Nm 160
Floating bearing stud bolt Nm 7
Locknut Nm 160
Reaction link
Reaction link to rear wheel drive Nm 43
Reaction link to frame Nm 43
Swinging arm to frame
Stud bolt, left/right Nm 160
Threaded ring, right Nm 200
Threaded ring, left Nm 10
Lock ring Nm 160
Spring strut
Spring strut to swinging arm Nm 50
Spring strut to frame Nm 43
[Option] Adjusting knob for spring strut to
rear frame Nm 21 Clean thread and Loctite 243

00.10
Model K 1200 RS
Connection
34 Brakes [Integral ABS]
Front brake
Brake caliper to fork tube Nm 30
Grub screw in front brake caliper Nm 7
Brake disc to front wheel Nm 21 Clean thread and Loctite 243
Brake hose/line/banjo bolt Nm 18
Brake fluid distributor to holder Nm 9
Holder to sliding tube Nm 4 Clean thread and Loctite 243
Bleed screw to brake caliper Nm 10
Rear brake
Brake caliper to rear wheel drive Nm 40
Brake disc to rear wheel drive Nm 21 Clean thread and install new screws
Bracket for ABS sensor to rear brake cali-
per, M6 Nm 8 Clean thread and Loctite 243
Master cylinder to footrest assembly Nm 9 Clean thread and Loctite 243
Brake hose/line/banjo bolt Nm 18
Bleed screw to brake caliper Nm 10
Pressure modulator
Pressure modulator to battery holder Nm 10
Filler adapter
Filler adapter to brake line Nm 18
Distributor for filler adapter to retaining
plate Nm 8
Grub screw in filler adapter Nm 10
Battery carrier
Battery carrier to rear mudguard Nm 6
Battery carrier to cross-tube Nm 6
Battery carrier to footrest plate Nm 18

00.11
Model K 1200 RS
Connection
34 Brakes [Optional extras, without Integral ABS]
Front brake
Brake caliper to fork tube Nm 30
Brake disc to front wheel Nm 21 Clean thread and Loctite 243
Brake hose/line/banjo bolt Nm 18
Brake fluid distributor to holder Nm 9
Holder to sliding tube Nm 4 Clean thread and Loctite 243
Bleed screw to brake caliper Nm 10
Rear brake
Brake caliper to rear wheel drive Nm 40
Brake disc to rear wheel drive Nm 21 Clean thread and install new screws
Bracket for ABS sensor to rear brake cali-
per, M6 Nm 8 Clean thread and Loctite 243
Master cylinder to footrest assembly Nm 9 Clean thread and Loctite 243
Brake hose/line/banjo bolt Nm 18
Bleed screw to brake caliper Nm 10
Filler adapter
Filler adapter to brake caliper, right Nm 18
Grub screw in filler adapter Nm 10
Battery carrier
Battery carrier to frame Nm 6
Battery carrier to cross-tube, M6 Nm 6
Battery carrier to footrest plate Nm 18
Model K 1200 RS
Connection
36 Wheels and tyres
Front wheel
Quick-release axle Nm 30
Quick-release axle clamp screws Nm 21
Rear wheel
Wheel studs Nm 105