1997–2005 BMW K 1200 RS Repair Manual – German (P/N 01 79 0 137 531)

This German-language BMW repair manual covers the 1997–2005 K 1200 RS. BMW publication 01 79 0 137 531, printed 03/01, documents workshop procedures for standard machines and original BMW accessories.

Text Search and Workshop Navigation

Searchable text and 683 bookmarks help you locate chapters and individual procedures. German search terms such as “Ventilspiel” and “Druckmodulator” find relevant passages. Exploded views, cross-sections and troubleshooting charts supplement the instructions; relay callouts and instrument wire-color legends remain readable when enlarged.

The download contains one printable PDF with 418 pages. That total includes nine opening pages: the cover, publication details, introductory guidance, three service sheets and the main contents pages. The maintenance schedule, delivery inspection and service-data sheets are embedded in the manual.

Engine Overhaul, Drivetrain Repair and Brake Service

Selected coverage below highlights the principal workshop sections. Further procedures include fairing removal and wheel balancing.

• Engine repair: Engine removal, cylinder-head and valve work, pistons, crankshaft bearings, camshaft timing, and combined oil/water-pump disassembly and assembly.

• Fuel injection and cruise control: Motronic MA 2.4 components, injectors, throttle controls, fuel-pressure testing, and cruise-control cable and control-unit work.

• Cooling system: Radiators, fans, thermostat replacement, leak testing, and troubleshooting charts for overheating, coolant loss and slow warm-up.

• Clutch and transmission: Dry-clutch replacement and alignment, hydraulic clutch components, gearbox dismantling, shaft bearings, shifting components and shimming.

• Telelever and Paralever: Fork seals, front suspension joints, steering damper, rear swingarm, driveshaft, final-drive bearings and gear adjustment.

• Brakes and Integral ABS: Caliper service, brake discs, sensors, pressure-modulator replacement, fluid changes, bleeding and BMW MoDiTeC checks.

• Electrical equipment: Ignition timing, alternator and starter service, switches, fuses, harness routing, instruments and lighting.

Written for workshop personnel, the manual assumes mechanical training and access to the specified tools. It also gives experienced owners a detailed reference for assessing the procedures, measurements and equipment a repair requires.

Engine Measurements and Valve Adjustment

Inspection stages I–IV, component torque tables, fluid information and wear limits support scheduled maintenance and component assessment. Bearing-clearance measurements and wear limits provide a reference for evaluating dismantled engine parts.

Valve adjustment involves camshaft removal and replacement bucket tappets. The instructions identify BMW camshaft alignment tool 11 3 700. A specific damage warning concerns piston position during camshaft and timing work: incorrect positioning can damage valves and pistons.

Gearbox and Final-Drive Repair Depth

Gearbox and final-drive cross-sections accompany dismantling and assembly instructions. Transmission coverage includes bearing adjustment and shimming; the intermediate shaft is replaced as an assembly apart from its ball bearings. Final-drive procedures address bearing preload, backlash and tooth-contact patterns.

The manual also warns that levering out the gearbox output-shaft seal with a screwdriver can damage the plastic shield of the bearing behind it.

Fault Charts and Electrical Illustrations

Cooling-system flowcharts organize checks for fan operation, coolant circulation and temperature-related symptoms. An intake-leak chart distinguishes checks around injector seals and intake connections, helping readers follow the documented diagnostic branches.

BMW MoDiTeC is referenced for fault-memory checks, throttle-related setup, fuel-reserve sender calibration and Integral ABS testing. Electrical illustrations show harness routing, relay locations and instrument wire colors; a complete circuit-diagram set is not included.

Integral ABS Circuits and Chassis Maintenance

Integral ABS procedures distinguish wheel circuits from control circuits and include filling, bleeding and subsequent diagnostic checks. Pressure-modulator coverage concerns removal and replacement. Separate maintenance instructions address machines without Integral ABS.

Steering-damper checks, stand lubrication and suspension-bearing checks extend the routine chassis coverage. BMW requires trained personnel for Integral ABS maintenance and repair; the relevant factory procedures and safety precautions remain essential.

A Preview of Cooling, Fuel-Pressure and Fastener Data

Cooling capacity: The manual specifies 2.5 liters for the cooling circuit and 0.6 liter for the expansion tank.

Fuel-pressure test: The specified pressure is 3.5 bar with the engine idling.

Cylinder-head bolts: The listed tightening specification is 20 Nm followed by a 90° angle, with the bolts and washers oiled.