BMW R 1200 GS 2003 Rider'S Manual Download

Page: 146 / 206

144

int

enanc

Air filter

Replacing air filter
element

• Make sure the ground is level

and firm and lift the motorcy-
cle onto its main stand

• Remove the front and rear

seats (

46)

• Remove the right side panel

as follows:

• Pull cover

out of its holders

• Turn two quick-action

adapters

counter-clockwise

to unlatch

• Working from inside, turn

quick-release adapter

counter-clockwise to unlatch

• Pull front panel

out of its

holders at the top front (see
marks) and remove

• Use T25 Torx bit to remove

three securing screws

and

remove rear panel

Summary of Contents for R 1200 GS 2003

Page 1: ...BMW Motorrad Rider s Manual R 1200 GS...

Page 2: ......

Page 3: ...make the best possible use of all your BMW s technical features In addition it contains informa tion on maintenance and upkeep to help you maintain your motorcycle s reliability and safety as well as...

Page 4: ...ime comes to sell your BMW please remember to hand over this Rider s Manual it is by law an important part of the vehicle Symbols and abbreviations d Warning This symbol indicates pre cautions and mea...

Page 5: ...instructions on how to per form a particular operation Figure in brackets b page number with explanations OE Optional extra Your motorcycle was assembled complete with all the optional extras you ord...

Page 6: ...ontain descriptions of equipment which you have not ordered If your BMW was supplied with equipment not described in this Rider s Manual such as a radio or anti theft alarm for example you will find t...

Page 7: ...e you will appreciate that no legal claims can be entertained on the basis of the data illustrations or descrip tions in this manual For your own safety d Warning Use only parts and accesso ries appro...

Page 8: ...accessories and other products which BMW has approved can be obtained from your author ised BMW motorcycle dealer together with expert advice on their installation and use The right clothing To reach...

Page 9: ...consequential damage due to repairs or serv ice work carried out by other than BMW authorised work shops Consequently we advise you to have service and maintenance work carried out by your author ised...

Page 10: ...s 20 Warning indicators 21 23 ABS warning lights 24 25 Operation 27 Ignition switch and steering lock 28 29 Electronic immobiliser EWS 30 31 Hazard warning flashers 32 33 Tripmaster 34 35 Kill switch...

Page 11: ...46 Jump starting 147 149 Battery maintenance instructions 150 152 Installing battery 153 154 Care 155 Cleaning care 156 159 Laying up 160 Restoring to use 161 Technical Data 163 Engine 164 Power train...

Page 12: ...10 i Introduction Contents...

Page 13: ...1 1 1 11 Overview General view left side General view right side Left handlebar fitting Right handlebar fitting Cockpit...

Page 14: ...ine oil filler neck b 112 113 8 Seat adjuster b 47 9 Luggage rack b 101 10 Seat lock b 46 48 11 On board socket 12 V for connecting electrical accessories b 93 12 Rear suspension strut shock absorber...

Page 15: ...ervoir for front brake b 116 20 Vehicle identification number 21 Air filter b 144 146 22 Helmet holder 23 Secondary spark plug b 143 24 Primary spark plug b 141 25 Spring strut adjuster rear b 51 26 B...

Page 16: ...the fitting on the handlebar Do not turn the handlebars in the clamping blocks 1 Button for Tripmaster b 34 2 Hazard warning flasher switch b 32 3 ABS buttonOE b 88 4 Horn switch 5 Left flashing turn...

Page 17: ...ircuit Do not turn the fitting on the handlebar Do not turn the handlebars in the clamping blocks 7 Emergency off kill switch for ignition b 65 8 Starter button b 67 9 Switch for heated handlebar grip...

Page 18: ...ess of the cockpit lights is be side the telltale light for the anti theft alarmOE 1 Speedometer 2 Rev counter b 68 3 Telltale and warning lights b 18 4 Multifunction display b 19 5 Telltale light for...

Page 19: ...1 2 17 Status indicators Telltale and warning lights Multifunction display Function indicators Warning indicators ABSOE warning lights...

Page 20: ...s 2 Telltale light high beam headlight q 3 Warning light general e b 86 4 Telltale light neutral k b 66 5 Warning light ABS l OE b 86 6 Telltale light right turn indicator t n depending on national m...

Page 21: ...b 20 10 Display panel for Tripmaster b 34 35 11 Display panel with clock b 38 Possible warnings 12 Oil pressure i b 21 13 Battery charge light r b 22 14 Bulb failure 7 15 Electronic immobiliser activ...

Page 22: ...ng to the gear you have engaged e yellow flashing n Fuel level When the fuel drops to the reserve level the n symbol appears in the display and flashes and General warning light e flashes The Tripmast...

Page 23: ...ferably an authorised BMW motorcycle dealer e red ON i Oil pressure Insufficient engine oil pressure b 112 113 Taking the traffic situation into account Disengage the clutch Operate the kill switch Br...

Page 24: ...authorised BMW motorcycle dealer e yellow ON 8 Bulb failure 8 Rear light or brake light defective replace bulbs b 134 6 7 Bulb failure 6 Front parking light low beam head light or high beam headlight...

Page 25: ...lay Meaning measure e yellow ON EWS Electronic immobiliser Key not recognised b 30 31 Communication with engine electronics disrupted L Note Various warnings may be is sued simultaneously Some warning...

Page 26: ...way test not completed b 86 OFF Flashes at 4 Hz Only RESIDUAL BRAKING FUNCTION available in both circuits b 85 because self diagnosis not completed b 86 Red ON OFF Brake light switch defective or not...

Page 27: ...uthorised BMW motorcycle dealer Ignition OFF brake pressure OK at the brake levers Brakes acting on both wheels Brake system leaktight no signs of brake fluid escaping Otherwise the brake system is de...

Page 28: ...2 26 Status indicators...

Page 29: ...switch and steering lock Electronic immobiliser EWS Hazard warning flashers On board computer Kill switch Heated handlebar gripsOE Setting the clock Adjusting the windscreen Handlebar levers Lights Se...

Page 30: ...cycle is fitted with BMW Integral ABSOE only the RESIDUAL BRAKING FUNC TION is available when the ig nition is switched off b 85 L Note Ignition switch and steering lock tank filler cap lock and seat...

Page 31: ...med b 64 V Ignition and lights off steering not locked handlebars can be turned freely to left or right The key can be removed in these positions 1 Ignition and lights off steering locked eAttention T...

Page 32: ...ised BMW motorcycle dealer bar individual keys for example if a particular key goes missing The engine cannot be started with a key that has been barred Function An electronic component is integrated...

Page 33: ...tion key Similarly physical force could damage the ignition key s inte gral electronics If this happens you will not be able to start the engine Spare extra keys You can obtain spare extra keys only t...

Page 34: ...han abso lutely necessary Note state of battery charge Switching on the hazard warning flashers Switch on the ignition ignition key in the U position Hazard warning flasher switch 1 lights up Operate...

Page 35: ...ndicators in the telltale lights panel go out Turn the handlebars to the position for locking the steer ing and lock the steering turn the ignition key to 1 The hazard warning flashers continue to ope...

Page 36: ...d B Tripmeter 1 C Tripmeter 2 D Residual range Residual range This reading appears only when the fuel level drops to reserve Residual range is estimated on the basis of style of riding and taking the...

Page 37: ...d the ignition switched on in other words when the ignition key is in the U position Repeatedly press button 1 Trip for less than 2 seconds until B tripmeter 1 Trip I or C tripmeter 2 Trip II appears...

Page 38: ...osition The electrical circuits for the electronic engine manage ment system instrument panel fuel pump and starter motor are de energised L Note If you move the kill switch to position B while the ig...

Page 39: ...ng L Note Grip heating can be activated only when the engine is run ning The increase in power consumption can drain the bat tery if you are riding at low en gine speeds Operate switch for heated hand...

Page 40: ...for longer than 2 seconds until the clock enters set mode Hours reading 2 starts flash ing briefly press button 1 to set Press button 1 again for longer than 2 seconds Minutes reading 3 starts flashin...

Page 41: ...nd right symmetrically and hand tighten the screws Slacking clamping screws 1 on left and right until the wind screen can be adjusted L Note You can set the windscreen to any of six different position...

Page 42: ...f you are doubtful about the re liability of the hydraulic clutch operating system consult a specialist workshop preferably an authorised BMW motorcycle dealer d Warning Do not attempt to turn adjust...

Page 43: ...justing the handbrake lever d Warning Do not attempt to turn adjust ing screw 1 while riding the motorcycle Turn adjusting screw 1 to set the most comfortable span Turn clockwise to increase span Turn...

Page 44: ...ing on the parking light L Note You can switch on the parking light only immediately after switching off the ignition when the ignition key is in the V position Switch off the ignition Press the left...

Page 45: ...peed Defective flasher bulb Similarly general warning light e and warning indicator 7 in the multifunction dis play b 19 both light up notify you if a bulb fails 1 Low beam headlight 2 High beam headl...

Page 46: ...adlight adjusted to suit whichever rule of the road applies eAttention Adhesive films with unsuitable adhesives can damage the headlight lens Headlight beam throw adjustment L Note Headlight beam thro...

Page 47: ...tting with motorcycle heavily loaded Only if the load carried on the motorcycle is very high the headlight beam can also be lowered by moving pivot lever 1 This shortens the beam throw Pivot lever 1 A...

Page 48: ...is difficult to turn the key in direction A pressing down firmly on the front seat will make the key easier to turn Turn the key in the seat lock to position B Remove the rear seat Turn the key in the...

Page 49: ...ways both be set to the same height Never set retainer 1 to the high position and retainer 2 to the low position or vice versa Remove the rear seat Remove the front seat and turn it upside down The fr...

Page 50: ...7 Slide the front seat into front lock 1 and press it firmly to secure it in position in the latching mechanism L Note Make sure that the tools are packed in such a way that the toolkit is as flat as...

Page 51: ...s In order to improve ergonomics or if a mirror arm has worked loose Push back protective cap 1 on the threaded fastener of the left or right mirror arm as applicable Use a w f 17 open ended spanner t...

Page 52: ...s level and firm and lift the motorcy cle onto its main stand Use the hooked wrench to adjust preload of spring to a stage between 1 and 9 3rd stage metalled road 5th stage loose gravel or similar 9th...

Page 53: ...cycle is being ridden Always bring the motorcycle to a stop before adjusting Adjusting spring preload rear wheel LOW setting one up Turn knob 1 as far as it will go counter clockwise in LOW direction...

Page 54: ...orber with a screwdriver and extension Basic setting one up Turn adjusting screw 1 as far as it will go clockwise in the direc tion indicated by the H arrow Turn adjusting screw 1 one and a half turns...

Page 55: ...ect tyre pressure Screw the valve caps back on tightly Tyre pressures for road tyres and massive bar tyres front rear One up 2 2 bar 2 5 bar 31 9 psi 36 3 psi Two up or luggage 2 5 bar 2 7 bar 36 3 ps...

Page 56: ...right and left Pack heavy items at the bottom and toward the inboard side Maximum load in each caseOA left and right 10 kg approx 22 lbs Maximum load in tank top rucksackOA and topcaseOA 5 kg approx...

Page 57: ...ot exceed the wheel load limits of 170 kg 375 lbs at the front and 280 kg 617 lbs at the rear Adjust shock absorbers front and rear rear wheel spring and tyre pressures to suit total weight b 50 53 Th...

Page 58: ...ng For safety reasons do not at tempt to change the position of the shift lever If you would like settings changed to suit your personal preferences please contact a specialist workshop preferably you...

Page 59: ...4 57 Riding Safety instructions Checklist First time out Before you start Starting Running in Shifting gear Off road riding Parking Refuelling Brake system general...

Page 60: ...vel is longer Risk of poisoning Exhaust fumes contain carbon monoxide which is colourless and odourless but highly toxic d Warning Inhaling exhaust fumes there fore represents a health haz ard and can...

Page 61: ...cycle dealer If misfiring or malfunction of the fuel air mixture preparation sys tem causes unburned fuel to reach the catalytic converter there is a risk of it overheating and being damaged Risk of f...

Page 62: ...ourney starts see the chapter entitled Maintenance in this manual or you can have it carried out by a specialist workshop preferably your authorised BMW motorcy cle dealer This is to ensure that your...

Page 63: ...reload Condition of wheels and tyres tread depth and tyre pressures Load gross weight Check that the luggage sys tem is secure Check regularly every time you stop for fuel Engine oil level every secon...

Page 64: ...motorcycle has not yet covered 1 000 kilometres approx 600 miles the engine is not yet fully run in eAttention BMW Integral ABSOE incorpo rates a brake booster so brak ing efficiency is significantly...

Page 65: ...cient unit Riding safely in traffic and off road calls for a sense of responsibility to your passenger and to other road users d Warning Do not ride the motorcycle af ter drinking alcoholic bever ages...

Page 66: ...they are described below Phase 1 A with General warning light e red Phase 2 B with General warning light e yellow and Phase 3 C without General warning light e Once the predrive check com pletes the v...

Page 67: ...sis is not performed unless both brake levers are in their fully re leased positions Only the RESIDUAL BRAKING FUNCTION is available until self diagnosis is completed b 85 L Note Starting on gradients...

Page 68: ...e light 1 green k lights up and gear indicator 2 in the multifunc tion display shows 0 L Note Engine does not start Move the gear lever to the k position or Do not pull the clutch lever until after yo...

Page 69: ...ill Avoid high engine speeds after a cold start L Note The start attempt is automati cally interrupted if battery volt age is too low Before trying again recharge the battery L Note Do not turn the th...

Page 70: ...h speed main roads and highways Running in engine speeds From 0 to 1 000 km 600 miles Engine speed max 4 000 rpm and no full load acceleration The first inspection should always be performed after 1 0...

Page 71: ...ompensated for by exerting greater pressure on the lever Try to avoid all unnecessary hard braking during this initial period eAttention Comply with the notes on BMW Integral ABSOE b 82 89 Tyres runni...

Page 72: ...ngine speed Do not use the high end of the engine revolutions range in any gear unless the engine is at operating temperature When the revolution counter needle enters the red zone on the dial the fue...

Page 73: ...4 71 Riding Gear shifts Gear shifts eAttention Always disengage the clutch in order to shift gear L Note Digital gear indicator 1 in the multifunction display tells you which gear is engaged...

Page 74: ...pressures when you return to metalled roads b 53 eAttention This motorcycle is a touring En duro machine which means it can also be used for light off roading on unsurfaced tracks If you are contempl...

Page 75: ...n the brakes increases the rate of pad wear BMW Integral ABSOE If you are riding off road or on a loose surface you might prefer to deactivate the ABS function b 88 89 Spring preload eAttention Adjust...

Page 76: ...rm On a gradient the motorcycle should always face uphill select 1st gear Switch off the ignition Pull the handbrake lever Hold the motorcycle upright and balanced Use your left foot to extend the sid...

Page 77: ...stand is fully retracted before you ride off Allowing the motorcycle to roll with the side stand extended represents a safety risk Ignition key in the V or U position Handlebars unlocked Both feet on...

Page 78: ...d is firm Switch off the ignition Hold the left handlebar grip with your left hand Grip luggage rack A or rear frame B with your right hand Place your right foot on the pin of the main stand and press...

Page 79: ...ly retracted before you ride off Ignition key in the V or U position Handlebars unlocked Hold the left handlebar grip with your left hand Grip luggage rack A or rear frame B with your right hand Push...

Page 80: ...the lower edge of the filler neck eAttention Leaded fuel will destroy the cat alytic converter Do not run the fuel tank dry or you may damage the engine or catalytic converter Fuel can damage plastic...

Page 81: ...he engine on fuel of a lower grade than 91 RON Capacity L Note The fuel gauge in the multifunc tion display works only when the ignition is switched on in other words when the ignition key is in the U...

Page 82: ...e has been washed ridden through water or ridden in the rain the brake discs and pads may be wet or iced over in winter and may not take effect immediately dWarning The brakes have to dry be fore they...

Page 83: ...edi ately because of dirt or mois ture on the discs or brake pads dWarning The brakes have to clean themselves before they start to bite Dirt on the brakes increases the rate of pad wear d Warning If...

Page 84: ...this reason the rider sel dom makes full use of available braking performance in an emergency BMW Integral ABS is the latest generation BMW Motorrad ABS development by preventing both wheels from loc...

Page 85: ...ensuring a safety margin in genuine emergencies You have to familiarise your self with the new electroni cally assisted braking Try the brakes several times when you take your motorcycle out for the...

Page 86: ...d every time the ABS controller comes into action In this partially integral brake configuration the integral brak ing function is activated only when you pull the handbrake lever The footbrake lever...

Page 87: ...ive the integral braking function is partially or entirely unavailable d Warning When the RESIDUAL BRAKING FUNCTION is active maintain a defensive riding style and pro ceed immediately to the near est...

Page 88: ...are in their fully released positions Only the RESIDUAL BRAKING FUNCTION is available until self diagnosis is completed b 85 Release the brake levers if necessary Switch on the ignition Initially ABS...

Page 89: ...r second slow flashing Flashing at 4 Hz 4 flashes per second fast flashing L Note Starting on gradients Always switch on the ignition with gear engaged clutch lever released and both brake levers rele...

Page 90: ...rface This is the reason why the ABS function of BMW Integral ABS can be deactivated Deactivating ABS d Warning Never switch the ignition off and on unless the motorcycle is at a standstill Brake boos...

Page 91: ...too hard and the front wheel locks or the rear wheel lifts clear of the ground as a result of a high level of front tyre adhesion With the motorcycle at a standstill switch off the ignition Press and...

Page 92: ...4 90 Riding...

Page 93: ...1 5 91 Accessories General instructions Power sockets 12 V Luggage system...

Page 94: ...yres market to ensure that it can be used on or in connection with BMW motorcycles with out constituting a safety haz ard Even approval by an official inspection authority or an official permit Genera...

Page 95: ...tage is low or the load exceeds the maximum rating Operating electrical accessories L Note You can start using electrical accessories only when the igni tion is switched on in other words when the ign...

Page 96: ...installed by a specialist workshop preferably an authorised BMW motorcycle dealer d Warning The wiring must be installed in such a way that the cable s do not impede the rider do not restrict or impe...

Page 97: ...led it is advisable not to exceed 130 km h 80 mph Opening system caseOA Turn the key in the case lock to position A Release latch 1 by pressing in the direction indicated by the arrow Hold down latch...

Page 98: ...2 at the sides engage with an audible click Fold down the carrying handle Lock the case and remove the key Changing case volume L Note Pivot lever 1 enables you to change the volume of the case Open...

Page 99: ...y An incorrectly secured case could be lost and endanger other road users Open carrying handle 3 Pull up red lever 4 latching flap 1 releases Pull latching flap 1 fully open Hold the case straight and...

Page 100: ...sits loose or refuses to latch Push red lever 7 b 99 down while pressing on latching flap 3 Latching flap 3 b 99 engages Engage locking lever 2 in the holder and close it Check the security of the cas...

Page 101: ...and pull it up b 95 Yellow rocker switch 6 and red lever 7 are accessible underneath the handle Open locking lever 2 Pull up lever 7 latching flap 3 releases Pull latching flap 3 fully open Window 4 t...

Page 102: ...Do not exceed the total weight limit of the cases L Note By removing the luggage rack with the rear seat removed and system casesOA installed you have a large flat luggage carrier to which you can sec...

Page 103: ...he procedure for installing the luggage rack is the reverse of the removal procedure Tighten three securing screws 1 to the specified tightening torque b 176 Install the system casesOA L Note When ins...

Page 104: ...5 102 Accessories...

Page 105: ...6 103 Arrive safely Reliable operation Service worldwide Training means extra safety...

Page 106: ...is too late to put them right at moderate cost The staff in the authorised BMW motorcycle dealer s workshop know every detail of your motorcycle and can take reme dial action if necessary before minor...

Page 107: ...They can provide prac tical advice on what to do next and can make arrangements on your behalf for example notify ing local emergency services anywhere in Europe recovery and transportation of the mot...

Page 108: ...ave the bend as smoothly as you entered it Allow for reaction time when judging braking distances At a speed of 50 km h approx 30 mph for instance one second s hesi tation means that about 14 metres 4...

Page 109: ...BMW Integral ABS Brake system with BMW Integral ABSOE Clutch Wheels Removing the front wheel Installing the front wheel Removing rear wheel Installing the rear wheel Checking brake pads Notes on chan...

Page 110: ...rider L Note Manipulation of the control unit of the electronic engine management system voids the warranty in all instances of damage consequential to such manipulation Whenever you are planning such...

Page 111: ...and gear engaged Fully retract the side stand b 66 Gear engaged clutch lever not pulled in Select neutral or disengage clutch b 67 Clutch pulled when ignition was OFF Switch on the igni tion then pull...

Page 112: ...visable to have other faults and work not described on pages 111 154 attended to by a specialist workshop preferably your authorised BMW motorcycle dealer LNote You can obtain further technical inform...

Page 113: ...50 miles Have the damaged tyre re placed at the earliest possible opportunity Remove the front seat b 46 Toolkit is then accessible Contents 1 screwdriver reversible blade 1 open ended spanner w f 17...

Page 114: ...only briefly or when it is not properly warm will falsify the reading and could lead to the engine being oper ated with the wrong quantity of oil because cold oil is viscous and takes longer to drain...

Page 115: ...il thorough filler neck 1 Reinstall oil filler plug 3 eAttention Red General warning light ein conjunction with engine oil pressure warning light i indicate no or very little oil pressure in the lube...

Page 116: ...checking d Warning Sudden changes in play or spongy action of the brake le ver indicate a fault in the brake system Before riding off therefore always check the resistance of the front and rear brake...

Page 117: ...per formed by a specialist workshop preferably an au thorised BMW motorcycle dealer Brake pad wear depends on your personal style of riding Frequent off roading in particu lar tends to accelerate the...

Page 118: ...sed BMW motorcycle dealer Make sure that the motorcy cle is upright Make sure the ground is level and firm Handlebars centred Check the brake fluid level in the reservoir MIN Minimum level L Note If t...

Page 119: ...authorised BMW motorcycle dealer Make sure the ground is level and firm and lift the motorcy cle onto its main stand Check the brake fluid level in the reservoir MIN Minimum level L Note If the motor...

Page 120: ...h system is filled with a special hydraulic fluid that does not have to be changed L Note The fluid level in the reservoir rises as the clutch wears eAttention Unsuitable hydraulic fluids could cause...

Page 121: ...ck for damage to the spokes Always have damaged spokes and irregular spoke tension rectified immediately by a specialist workshop preferably an authorised BMW motorcycle dealer Make sure the ground is...

Page 122: ...cle dealer or by visiting www bmw motorrad com maintenance on the Internet Checking tyre tread depth Road tyres and massive bar tyres d Warning Comply with local legal re quirements concerning mini mu...

Page 123: ...ight eAttention When removing do not dam age brake pipes brake discs brake pads and the wheel rim mask off with tape if necessary Do not scratch the rim when forcing back the brake pads or removing th...

Page 124: ...or to either side Use a Torx T45 bit to remove securing screws 1 for the left and right brake calipers Push the brake pads back a little by lightly rocking the brake calipers Carefully take off the le...

Page 125: ...ocket wrench and a w f 17 open ended spanner Use the spark plug wrench for more leverage b 111 Roll the front wheel forwards and out Remove spacing bushing 3 from the wheel hub eAttention When setting...

Page 126: ...te arrow on tyre indicating correct direction of rotation d Warning Make sure that the motorcy cle is standing firmly and can not topple forwards or to either side On left as viewed in forward directi...

Page 127: ...completed pull the handbrake lever after the ignition has been switched on and self diagno sis has completed Remove front wheel stand Compress the front forks firmly several times Tighten axle 1 to th...

Page 128: ...ll the handbrake lever several times With BMW Integral ABSOE Switch on the ignition Wait for self diagnosis to complete Pull the handbrake lever eAttention Always have the tightening tor ques checked...

Page 129: ...ft the motorcy cle onto its main stand d Warning Make sure that the motorcy cle is standing firmly and can not topple to the rear or to either side eAttention Do not damage brake lines brake disc brak...

Page 130: ...the T50 Torx wrench b 111 to remove five wheel studs 1 Use the spark plug wrench b 111 for more leverage Lift the rear wheel clear of its centring spigot tilt it lower it to the ground and remove it e...

Page 131: ...sure not to mix up the wheel studs or use a mixture of the two lengths eAttention Use only wheel studs with the same length code number Do not oil or grease the wheel studs Do not damage brake lines...

Page 132: ...of grease Insert rear wheel into centring hole Hand tighten wheel studs 1 and then tighten in diago nally opposite sequence to the specified tightening torque b 176 eAttention Always have the tighten...

Page 133: ...n stand Visually inspect both sets of brake pads and brake cali pers and make sure that they all bear the same colour mark 2 Visually check brake pad thickness Minimum pad thickness Wear indicator 1 m...

Page 134: ...lift the motorcy cle onto its main stand Visually check brake pad thickness Minimum pad thickness Make sure that the brake disc is not visible through bore 1 in the inboard brake pad If the brake dis...

Page 135: ...r the parking light one for the brake light rear light plus four bulbs for the turn indi cators A bulb failure is indicated by 7 in the multifunction dis play in some instances in com bination with th...

Page 136: ...re the ground is level and firm and lift the motorcy cle onto its main stand Use a screwdriver to remove securing screws 1 Remove rear light glass 2 Press bulb 3 into its socket and disengage it by tu...

Page 137: ...ve gloves risk of injury eAttention Switch off the ignition before changing a bulb Risk of short circuit Make sure the ground is level and firm and lift the motorcy cle onto its main stand Turn the ha...

Page 138: ...1 on left and right and swing the clip open Pull H7 bulb 2 out of its bulb socket Installation is the reverse of the removal procedure L Note Insert H7 bulb 2 with lug 4 in guide 5 Make sure that wor...

Page 139: ...ve gloves risk of injury eAttention Switch off the ignition before changing a bulb Risk of short circuit Make sure the ground is level and firm and lift the motorcy cle onto its main stand Turn the ha...

Page 140: ...s 2 at top and bottom and swing the clip open Pull H7 bulb 1 out of its bulb socket Installation is the reverse of the removal procedure L Note Insert H7 bulb 1 with lug 5 in guide 4 Make sure that wo...

Page 141: ...rt circuit Make sure the ground is level and firm and lift the motorcy cle onto its main stand Turn the handlebars all the way to the right Pull bulb holder 2 out of the headlight housing Pull bulb 1...

Page 142: ...ure the ground is level and firm and lift the motorcy cle onto its main stand Remove securing screw 1 with screwdriver Remove flashing turn indica tor glass 3 Press bulb 2 into its socket and disengag...

Page 143: ...or wiring Risk of fatal accident Work on the electrical system only when the circuit has been interrupted switch off the ignition Changing primary spark plug Make sure the ground is level and firm and...

Page 144: ...stallation is the reverse of the removal procedure Tighten the spark plug to its specified torque b 176 eAttention Make sure the spark plug cover is correctly seated Always have the tightening torque...

Page 145: ...111 Remove spark plug cover 2 Remove direct ignition coil 3 Use the spark plug wrench and screwdriver b 111 to remove the spark plug Installation is the reverse of the removal procedure Tighten the sp...

Page 146: ...ear seats b 46 Remove the right side panel as follows Pull cover 5 out of its holders Turn two quick action adapters 2counter clockwise to unlatch Working from inside turn quick release adapter 3 coun...

Page 147: ...the rear to release and remove Remove intake 1 eAttention Make sure that the throttle valve cable is not disengaged when you remove the air filter element Pull the old air filter insert for ward and d...

Page 148: ...ousing B L Note This procedure for removing and installing the air filter ele ment prevents dirt from enter ing the air filter housing From this point on installation is the reverse of the removal pro...

Page 149: ...the battery is completely flat In this case do not attempt to jump start the motorcycle re charge the battery instead Risk of damaging the control units L Note Do not use proprietary start assist spra...

Page 150: ...gine is running Risk of fatal accident L Note On your motorcycle use the battery adapter point on the positive terminal and the spring strut screw as the ground connection when con necting the jump le...

Page 151: ...negative terminal of the dis charged battery Start the engine of the donor vehicle and allow it to run for the duration of the jump start procedure Start the engine of the vehicle with the discharged...

Page 152: ...and are essential if warranty claims are to be considered Charging the battery when installed and connected The battery has to be charged at regular four weekly intervals if the motorcycle is laid up...

Page 153: ...acces sories if any connected to the second on board socket Switch on the ignition Plug in the charger Switch off the ignition L Note The motorcycle s on board electronics know when the bat tery is f...

Page 154: ...le clips from the battery terminals If the battery is in storage for an extended period of time recharge it at regular intervals of approx 4 months Always fully recharge the bat tery before restoring...

Page 155: ...lead Make sure the ground is level and firm and lift the motorcy cle onto its main stand Remove the front and rear seats b 46 Use the screwdriver to dis connect negative battery lead 1 Open protective...

Page 156: ...engaged To avoid short circuits Connect the positive battery lead 3 first Close protective cap 2 for the positive battery post Never install the battery without the protective cap Connect negative bat...

Page 157: ...8 155 Care Washing the motorcycle Removing road salt Cleaning the windscreen Cleaning care Touching up minor damage Care of exhaust silencer Cleaning care Laying up Restoring to use...

Page 158: ...to clean the seat Do not use a steam jet or high pressure cleaning equipment High water pressure can dam age seals the hydraulic brake system or the complete electri cal system L Note Regular cleaning...

Page 159: ...arbox and swinging arm in accordance with the manu facturer s instructions Thoroughly dry all wet surfaces Do not use solvents or clean ing agents to clean the instru ment panel switches and windscree...

Page 160: ...wax based corrosion proofing product to chrome plated parts Coat polish fairing elements after cleaning and drying with a recommended wax Cleaning the windscreen eAttention Do not use cleaning agents...

Page 161: ...ched up with a BMW touch up pencil of the correct colour L Note Have severe damage repaired by a specialist workshop pref erably your authorised BMW motorcycle dealer Care of exhaust silencer Changes...

Page 162: ...room Support the motorcycle under the engine so that the wheels are not taking any weight L Note Before laying the vehicle up out of use have the engine oil and the oil filter element changed by a spe...

Page 163: ...cessary remove protec tive wax coating Clean the motorcycle b 157 Install a charged battery b 153 154 Perform all safety checks b 60 Check the brakes b 80 88 b 114 117 and b 131 132 Check correct tyre...

Page 164: ...8 162 Care...

Page 165: ...9 163 Technical data Engine Power train Frame and suspension Fuel and lubricants Electrical system Dimensions and weights Performance data Tightening torques...

Page 166: ...x torque 115 Nm at engine speed 5 500 rpm Permissible engine speeds Engine speed maximum 7 800 rpm Idle speed 1 150 50 rpm Bore stroke 101 73 mm 4 2 9 in Compression ratio 11 0 1 Fuel consumption to I...

Page 167: ...th claw shift and integral torsional vibration damper Gear ratios 1st gear 4 15 2nd gear 2 89 3rd gear 2 30 4th gear 1 88 5th gear 1 65 6th gear 1 47 Transmission from gear box to rear wheel drive Uni...

Page 168: ...ocation of type plate Behind left side cover Location of vehicle identifi cation number VIN On front frame at right Front brake Two floating brake discs with 4 piston fixed calipers Sintered metal bra...

Page 169: ...9 167 Technical data R 1200 GS Wheel location Front BMW Telelever Rear BMW EVO Paralever swinging arm Steering lock angle 2 x 42 Frame and suspension...

Page 170: ...avel 190 mm 7 5 in Fixed tube diameter 41 mm 1 6 in Front wheel castor in normal load position 110 mm 4 3 in Rear suspension system Central spring strut with single tube shock absorber with progres si...

Page 171: ...your authorised BMW motor cycle dealer or by visiting www bmw motorrad com maintenance on the Internet Front wheel Angled rim shoulder and double tyre retaining hump Rim size 2 50 x 19 Tyre size 110...

Page 172: ...3 psi Rear 2 70 bar 39 2 psi Two up and luggage Front 2 50 bar 36 3 psi Rear 2 90 bar 42 psi Recommended minimum tyre tread depth Comply with local legal requirements concerning minimum tread depth d...

Page 173: ...or the individ ual SAE classifications are permitted for brief periods only All engine oils supplied by BMW are subject to regular BMW quality assurance checks BMW does not approve the use of any uppe...

Page 174: ...ed fuel to DIN 51 607 standard minimum octane number 95 RON Fuel tank capacity usable 20 l 4 4 gal including approx 4 l 0 9 gal reserve Brake fluid DOT 4 We recommend BMW brake fluids eAttention Use o...

Page 175: ...fuse trips and de ener gises a circuit the circuit is active as soon as the ignition is switched on after the fault has been rectified Headlights Twin halogen headlights Bulbs High beam headlight H7 h...

Page 176: ...840 860 mm 33 1 33 9 in Wheelbase in normal load position 1 520 mm 60 in Ground clearance in normal load position 187 mm 7 in DIN unladen weight 225 kg 496 lbs Dry weight to EU specification 211 kg 46...

Page 177: ...l data R 1200 GS Top speed 208 km h 129 mph Ride past noise level to EU specification 79 dB A Stationary noise level to EU specification 87 dB A at 3 500 rpm Acceleration 0 100 km h 0 62 mph 3 4 s Per...

Page 178: ...ck release axle 50 Nm Axle clamping screw 19 Nm Rear wheel Wheel studs 60 Nm Spark plugs Primary spark plug Engine cold 22 5 Nm Secondary spark plug Engine cold 22 5 Nm Battery Battery terminal clamps...

Page 179: ...rther 20 000 km 12 000 miles 30 000 km 50 000 km 70 000 km 18 000 miles 30 000 miles 42 000 miles if covered within a year BMW Inspection After the first 20 000 km 12 000 miles and every further 20 00...

Page 180: ...r reading Brake fluid changed Without BMW Integral ABS With BMW Integral ABS Wheel circuit Control circuit Clutch fluid changed Date stamp signature BMW Pre delivery Check Carried out in accordance wi...

Page 181: ...anged Without BMW Integral ABS With BMW Integral ABS Wheel circuit Control circuit Clutch fluid changed Date stamp signature BMW Service BMW Annual Inspection BMW Service BMW Inspection Carried out in...

Page 182: ...nged Without BMW Integral ABS With BMW Integral ABS Wheel circuit Control circuit Clutch fluid changed Date stamp signature BMW Service BMW Annual Inspection BMW Service BMW Inspection Carried out in...

Page 183: ...anged Without BMW Integral ABS With BMW Integral ABS Wheel circuit Control circuit Clutch fluid changed Date stamp signature BMW Service BMW Annual Inspection BMW Service BMW Inspection Carried out in...

Page 184: ...nged Without BMW Integral ABS With BMW Integral ABS Wheel circuit Control circuit Clutch fluid changed Date stamp signature BMW Service BMW Annual Inspection BMW Service BMW Inspection Carried out in...

Page 185: ...anged Without BMW Integral ABS With BMW Integral ABS Wheel circuit Control circuit Clutch fluid changed Date stamp signature BMW Service BMW Annual Inspection BMW Service BMW Inspection Carried out in...

Page 186: ...nged Without BMW Integral ABS With BMW Integral ABS Wheel circuit Control circuit Clutch fluid changed Date stamp signature BMW Service BMW Annual Inspection BMW Service BMW Inspection Carried out in...

Page 187: ...of maintenance warranty and re pair work of the installation of optional accessories and also to confirm that special campaign work has been carried out Record of all work carried out in workshop Wor...

Page 188: ...186 Service 10 Record of all work carried out in workshop Work performed km miles Date Confirmation of service...

Page 189: ...hazard invali date the motorcycle s general operating permit or cause you to lose your insurance cover Technical modifications should always be entrusted to your authorised BMW motor cycle dealer L N...

Page 190: ...188 Service 10...

Page 191: ...pection notes 177 Anti lock braking system deactivating 88 Attention 2 Axle clamping screw 123 B Battery charging 150 charging when connected 150 charging when disconnected 152 installing 154 removing...

Page 192: ...aint damage 159 removing road salt 158 washing 157 Clock 19 20 Closing the system case 96 Clutch 165 fluid level 118 Clutch lever 40 Clutch lever adjusting 40 Cockpit 16 general view 16 Compression ra...

Page 193: ...ety 5 Frame 166 Front brake Checking brake fluid level 116 Front brake brake fluid reservoir 13 Front seat adjusting 47 Front suspension 50 Front wheel technical data 169 Front wheel stand 121 Fuel 78...

Page 194: ...talling seat 48 Installing system case 97 Installing the front wheel 124 126 Installing the rear wheel 129 Instruments cockpit 16 J Jump starting 147 148 149 K Key positions 29 Keys 28 Kill switch 36...

Page 195: ...cket 12 V cable routing 94 Predrive check 64 Pull away test 87 Q Quantity of oil 112 Quick release axle 123 R Rear shock absorber adjusting 52 Rear wheel technical data 169 Rear wheel drive technical...

Page 196: ...ring bulky luggage 100 Self diagnosis with pull away test 86 Service Card 105 Service worldwide 105 Service notes 177 Setting the clock 38 Shift lever 56 Shifting gear 79 Shock absorber adjustment 52...

Page 197: ...ading 2 34 Troubleshooting 109 Troubleshooting chart 109 110 Tubeless tyres 111 Turn indicator bulbs 140 Turn indicator cancel switch 15 Turn indicator switch left 14 right 15 Type plate 13 166 Tyre d...

Page 198: ...196 i Index W Z Wheels 119 120 121 124 not approved 120 Wheels technical data 169...

Page 199: ...rship data Vehicle data Model Vehicle identification number Colour code First registration Registration number Dealership data Person to contact in Service Ms Mr Phone number Dealership address phone...

Page 200: ...ade The difference between the min and max marks is equal to approximately 0 5 litre 0 9 pint Tyre pressures Front Rear One up 2 20 bar 31 9 psi 2 50 bar 36 3 psi Two up 2 20 bar 31 9 psi 2 70 bar 39...

Page 201: ...ns What happens with bumps in the road Corrugated road surfaces or bumps in the road can cause the tyres to temporarily lose contact with the road surface and hence the braking force it is possible to...

Page 202: ...control function is no longer fulfilled Field observations carried out by BMW Motorrad indicate that a comparable situation has not arisen in traffic or even during training rides The following notes...

Page 203: ...vo action remain opera tional If these systems also fail the residual brake function is applied In this case the forces to be applied to the brake levers will be signifi cantly higher and the lever tr...

Page 204: ...tion What is the design specification for BMW Motorrad Integral ABS BMW Motorrad Integral ABS ensures stability of the motor cycle on any surface within the bounds of physics The system is not designe...

Page 205: ...fall Lack of due care when trans porting the motorcycle Threaded fasteners working loose Impermissible ergonomic set tings see Rider s Manual Adjusting clutch lever han dlebar lever or as applicable...

Page 206: ...fully forward Turn the hand protec tor until the tip of the handlebar lever touches the cross on the label Have the settings and the threaded fastener tightening torques checked by a special ist works...

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BMW R 1200 GS 2003, Rider'S Manual

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