BMW K1200 S superbike production starts

BMW Motorrad Duolever
The BMW K1200S shines with a completely new front wheel suspension, which, instead of the normal telescope fork suspension, provides extremely sensitive throttle response thanks to two parallel longitudinal links. Decoupled from the suspension and damping function the revolutionary Duolever leads the power optimally into the frame structure and brings about an absolutely new frame concept due to the deep connection: a large aluminium frame now consisting of nine different component parts. A new concept for the machining of the K1200S frame had to be found. The concept: An island of machine tools with two interlinked machining centres. The aluminium cast and forged parts as well as the welded frames are transported autonomously to the next vacant machining centre on mobile work piece carriers controlled by means of transponder technology. In dry machining– and without the obligatory cooling lubricant - the components are machined here at high speed. The new front wheel guidance BMW Motorrad Duolever and the optional electronically adjustable chassis will cause a few raised eyebrows. Here are the benefits: 1. Maximum rigidity 2. Maximum braking and ride stability	What makes the Duolever principle an innovation? It revolutionises front wheel guidance for motorcycles. Since wheel guidance is separated from damping, an excellent feel for the road is developed – probably one of the most important requirements for sporty motorcycling on the road. With two combined triangular control arms and the wheel carrier, a four-link system is formed which ensures improved traction and comfort as compared to the Telelever. ESA: innovation at the press of a button. This abbreviation stands for greater comfort and flexibility on the road: Electronic Suspension Adjustment (ESA). The rider sets the spring pre-load tension and damping by pressing a button on the handlebars. It is optionally available.


Shaft drive: a drive train with plenty of strengths. Narrower, lighter, slimmer - this is what makes the newly designed shaft drive from BMW Motorrad so interesting. With the significantly slimmer EVO Paralever, the “jack-up” effect at load change is more effectively compensated. Another benefit: the shaft drive is completely maintenance-free, thus minimising costs for maintenance and service from the start.
	Engine and suspension components
A high-performance engine needs high-performance components. With a considerably lighter crankshaft and a crankcase constructed as a lightweight unit, the powerful BMW K1200S engine reaches revving speeds in the five-digit range. Larger but more filigree was the premise concerning the crankcase: after all, the 1157 cc 4-cylinder in line engine as well as an integrated gearbox had to be installed. The crankcase construction of the free-revving street sports bike is thus more complex than all previous crankcases and makes greater demands on machining, and hence greater demands on the machinery and tools:
	The crankcase is being cut for the first time by tools with base bodies made of titanium. At the same time, new and extremely flexible machines are being used in production, such as the honing centre, for example, where the K1200S 4-cylinder engine as well as all the other 4-cylinder engines of all other models of the K-series now get their last high-precision finishing touch in the cylinder barrels.
Engine assembly The heart of the sports package – the BMW K1200S engine – is produced at the new very flexible engine assembly plant. Within two hours, the 1157 cm³ 4-cylinder in line engine with the maximum engine performance of 123 kW (167 Bhp) and the impressive torque of 130 Nm is assembled and tested. The production of the integrated 6-speed cassette gearbox requires a very special technical solution, however: For the first time in the world we are combining the cold test and transmission test at one plant. All readings measured on the driven engine - torque, rotational speed, noise emissions or various hydraulic pressure tests – thus provide extensive information about the perfect assembly of the most important engine components and their function at an extremely early point in time.
	One reason for the incredible power and sportiness of the BMW K1200S: A filigree engine and valve train construction to catapult the 4-cylinder in line engine to rotational speeds of up to 10.250 min -1 with few moving masses. The solution: The 16 valves of the double overhead camshaft engine are actuated by light and rigid cam followers. Consequently, new and technically advanced equipment was essential for the valve train assembly and adjustment. The valve clearance of the K1200S high-performance power plant is set by hemispheres that can only be used with very complicated handling tools. In this process, the correct size of the hemispheres is critical for the valve clearance: The new equipment that is inserted in the cam follower on one side checks whether the valve clearance is correct. If this is not the case, the plant calculates the correct size of the hemisphere fully automatically and restarts the process of valve clearance measurement after exchanging the hemispheres.
Motorcycle assembly The rear axle differential of the BMW K1200S – just like with the BMW R 1200 GS - is a completely new design. To master perfectly all the one hundred variants of a BMW Motorrad rear axle, they are produced on an exclusively constructed assembly line. All sorts of different jobs in succession logistically perfectly coordinated. From a technical point of view, the new plant leaves nothing to be desired: The gear clearance, now with 3600 test points per revolution on the gear wheel, provides extremely accurate data about the overall gearing, whereas the improved adjustment design also provides a robust K1200 S axle. Another new feature is the automatic leakage test and automatic filling of oil with type-specific and gram-precise oil dosing of the rear axle differential.
	A special feature of the sporty BMW K1200S is its electronic vehicle electrics. All vehicle relevant data are transmitted to the five integrated control units in the motorcycle via CAN-Bus. Just like bus stops along a bus route the engine management, central suspension electronics, instrument cluster, theft warning system and ABS electronic control unit communicate only via one connection. The keyword in motorcycle assembly is Cascade (Control Application Sequences for Coding and Diagnostics Execution) which incorporates an extremely reliable electronic Check-Out-Test. Cascade works in the following way: After the individual vehicle data is available through the scanning process, Cascade checks all the essential and required functions such as the indicator lights, stop light as well as internal sensors in a pre-programmed sequence. Cascade and control units exchange information and operating instructions via a radio link. The test process and results can be seen directly in the digital information screen on the assembly line.

Technical specifications.

		K1200S
Engine
Capacity	cc	1157
Bore/stroke	mm	79/59
Output	kW/Bhp	123/167
at engine speed	rpm	10250
Torque	Nm	130
at engine speed	rpm	8250
Type		Inline
Number of cylinders		4
Valve control		DOHC ( double overhead camshaft)
Valves per cylinder		4
Carburation/engine management		Digital engine electronics with integrated knock control (BMSK)

Power transmission
Clutch		Multi-disc wet clutch
Gearbox		Constant-mesh 6-speed gearbox
Drive		Shaft drive
Chassis
Frame type		Aluminium composite frame
Front wheel suspension		BMW Duolever
Rear wheel suspension		BMW Paralever
Travel front/rear	mm	115/135
Castor	mm	112
Wheelbase	mm	1571
Steering head angle	°	60.6
Brakes	front	EVO brake system, Dual disc Ø 320 mm
	rear	Single disc Ø 265 mm
		BMW Motorrad Integral ABS (part-integral) as standard
Wheels		Cast light alloy
	front	3.50 x 17 MTH 2
	rear	6.00 x 17 MTH 2
Tyres	front	120/70 ZR 17
	rear	190/50 ZR 17

Dimensions and weights
Seat height	mm	820 (790)
Weight according to DIN standard, fully fuelled, road ready	kg	248
Max loaded weight	kg	450

Riding data
Fuel consumption
90 km/h	l/100 km	4.7
120 km/h	l/100 km	5.5

Well I survived the Nordschliefe! Rather than writing some glittering prose (that's the journo's job) I'll point out a few things that stuck in my mind:

I have taken some photos which can be viewed in full by clicking on the small pictures below.

BMW K1200S