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"KRS/GT" Technical Q&A K1200RS/GT Technical Questions/Answers

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  #1  
Old 01-29-2014, 11:53 AM
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K1200RS/GT Ignition switch. Clean now...

Before I forget....

Procedure in Clymer is OK on removing the switch "electrical component" but as usual for Clymer, pics aren't very good. Not that mine are either but.....

The "blind screw" with the red lacquer removed. No need to make a tool/grind a screwdriver as per Clymer, the eyeglasses screwdrivers fit there and you'll need them later to open the "electrical component".




Make fun of my carpeted shop all you want....sure comes in handy to keep little parts from bouncing away.





I had the electrical "jack in the box" open , so I took the switch right out. Big orange connector:



Switch and Clymer at the right page.




And then just a matter of prying off the cover and switch body apart with the small screwdrivers. 4 springs, three moving parts, plenty of dirt and some green grease in the wrong places.

Note the wire cover, it has a drain hole just where all the dirt is. Third pic below shows the other smaller drain hole that goes to the mechanism. Dirt and water will go into the switch that way. Dirt here???....often salty.










Clean??? This should be good???Better be, that's all the local store had.



Lube????....now that's good stuff:

http://www.westmarine.com/webapp/wcs/stores/servlet/ProductDisplay?catalogId=10001&storeId=11151&productId=44195 2&langId=-1

At the same time I cleaned the tumblers/ mechanism. I think the electrical cleaner will do it and then a squirt of Teflon Dry lube. DRY lube in the tumblers, I already asked the local locksmith/welder/fabricator.







And then working from the bottom up, cleaned the steering lock mechanism. No pics of that but again lots of OEM grease in the wrong places. That's what came out, no wonder my switch action wasn't smooth. To the point of thinking that I may not be able to unlock my steering.



Sprayed lube in there....good old Castrol chain lube. Comes out liquid and then thickens up. Works just as good as other products and cheap.

Switch...cleaned/lubed,ready to go back with a little paint dot to help lining up:





And then a drop of that in the blind screw hole, I don't want it to come out, may have to start the bike with a screwdriver if that happens....



Lost your keys??? Want your bike started??? I'd rather not say how easy that would be without breaking anything. Use the steering lock!!!!
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  #2  
Old 01-29-2014, 01:21 PM
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Re: K1200RS/GT Ignition switch. Clean now...

Pierre, this is FANTASTIC write-up and I am sure it will be useful to K1200RS/K1200GT owners... one day... when they badly need it.

Keeping ALL pictures in my archive in case of emergency ;-)
Thank you!
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Old 01-29-2014, 01:30 PM
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Re: K1200RS/GT Ignition switch. Clean now...

Thanks Pierre, I've made the thread into a "sticky" so it will be readily accessible!
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Old 01-29-2014, 01:52 PM
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Re: K1200RS/GT Ignition switch. Clean now...

Quote:
Originally Posted by sailor
Keeping ALL pictures in my archive in case of emergency ;-)
Thank you!

Emergencies ...Eh I am trying to prevent that on my bike. But thinking about roadside emergencies, if you read about them drain holes up there, could be just a matter of removing the switch and then spray contact cleaner in there without opening it up.

And the holes line up, so one may not even need to remove the switch in an emergency, just spray in from under.

Losing any of the parts when doing that in an emergency, now that would be a real emergency.
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Old 01-29-2014, 06:14 PM
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Re: K1200RS/GT Ignition switch. Clean now...

Good stuff. Thanks for sharing.
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Old 02-02-2014, 03:23 AM
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Re: K1200RS/GT Ignition switch. Clean now...

Nice one Pierre. I like going into small places to clean... BTW who out there keeps a spare key taped to the bike in a secure place? If you loose your key it is sure comforting to know you have a another carefully hidden on the bike. I used the oem key that has no bulky plastic on it so it is nice and slim.
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  #7  
Old 02-02-2014, 10:40 AM
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Re: K1200RS/GT Ignition switch. Clean now...

Quote:
Originally Posted by Flying Kiwi
Nice one Pierre. I like going into small places to clean... BTW who out there keeps a spare key taped to the bike in a secure place? If you loose your key it is sure comforting to know you have a another carefully hidden on the bike. I used the oem key that has no bulky plastic on it so it is nice and slim.

Spare key....the one on my car sure came in handy yesterday.

On the bike....not on that one but always one in my old leather jacket. That jacket even has a tether built in for keys.

I should order one of them cheap ebay blanks,apparently they don't work but we have established a relationship with the local locksmith....he is also a fabricator and one of the best Aluminium welder I have met for a long time, he may be able to do something with them cheap blanks.

Small places to clean.....I am running out of them for sure. For some reason I knew you'd say that. Off to write a thread on "Starter removal" and maybe show some dirt.
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Old 03-17-2015, 02:49 PM
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Re: K1200RS/GT Ignition switch. Clean now...

Great write-up and pics Pierre. Thanks!
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  #9  
Old 04-04-2015, 05:35 PM
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Re: K1200RS/GT Ignition switch. Clean now...

This is a great post! I actually had to put this to use as my ignition was full of dirt and road grime just this past week. A full cleanup as shown and a good ground at the battery and everything is back to normal. Thanks!
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Old 09-15-2015, 07:21 PM
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Re: K1200RS/GT Ignition switch. Clean now...

Is there a fastener holding that plastic connector at the bottom of the switch? Mine fell out while I was getting fuel today. Went back in a little too easily, I'm thinking if nothing has fallen out the plastic tabs that snap it into place must be worn or broken.
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Old 09-16-2015, 01:11 PM
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Re: K1200RS/GT Ignition switch. Clean now...

If that whole unit with the wiring fell out, I would say the very small set screw that holds the switch in place has either backed out or fallen out. It should have been sealed in at the factory and is located on the right side of the fork housing assembly. The sealant comes out easily and the set screw will come out or tighten with a small eye glasses screw driver. After resetting the screw, cover the area where the screw goes in with some RTV to keep the area clean.

Now, if just the plastic cover has fallen out I would say there are some important issues to address quickly as there are brass contacts and very small springs inside there that make all this work properly. The plastic snaps for the cover don't seem to break but they gather so much road dirt that they won't hold there position properly. That's why the cleaning is so important in that area. I did a full tear down of the switch (very carefully...springs and brass contacts are very small) and cleaned everything inside. Take pictures of your steps so you can see how it goes back together.

I would review the initial post with the pictures again to be sure what has happened to your ride.

Keeping that switch clean has turned out to be a must check item if you ride in dirt/mud or rain a lot and I found using brake cleaner spray in the area does the trick.

Check it out and let us know what you find.
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Old 09-17-2015, 07:55 PM
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Re: K1200RS/GT Ignition switch. Clean now...

The hole my set screw goes into is broken. I'll have to see if the missing piece is stuck inside the housing. Worst case scenario I could machine a new plastic piece for the set screw, cut the broken piece off, then glue the new one on.
https://www.dropbox.com/s/uh052srzyu...057-1.jpg?dl=0
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Old 09-19-2015, 07:35 AM
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Re: K1200RS/GT Ignition switch. Clean now...

Hey, what were the symptoms that lead you to strip out and clean this?
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  #14  
Old 09-19-2015, 09:58 AM
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Re: K1200RS/GT Ignition switch. Clean now...

Quote:
Originally Posted by clone5
Hey, what were the symptoms that lead you to strip out and clean this?

Symptoms? None on my bike but there were some from other posts before that. Preventive me....!

And as per the still valid BMW service bulletin, all electrical connections should be cleaned and lubed every year. Old bulletin....better dielectric lubes nowadays so every couple years.
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Yamaha RD350 at 17
Honda CB750F at 18
Honda V45 Sabre at 24
85 BMW K100RS at 28 (Very nice and sorely missed)
90 BMW R100GS at 34 (Too slow, too cranky)
2003 K1200 RS at 53 (Oh Yeah......over 6000RPM)
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Old 12-03-2015, 05:36 AM
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Re: K1200RS/GT Ignition switch. Clean now...

Thank you - I performed this surgery.
I went for a ride the other day and the wires leading to the ignition switch fatigued and ultimately severed.
Taped it up and rode home with the engine stopping any time I turned the handlebars more than half lock to the right.

Surgery went well. I ended up cutting the wires about 6 inches down and running new wires into the switch. You know the drill, de-solder/re-solder heatshrink...

I rejoined the 5x wires with a molex connector for the time being and all works very well.

Much appreciated
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Old 05-21-2016, 12:21 PM
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Re: K1200RS/GT Ignition switch. Clean now... Any grease used on contacts

Just asking if you used any type of grease on the contacts, rotor portion of the switch to keep being metal to metal or if it is not needed.
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Old 05-21-2016, 02:31 PM
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Re: K1200RS/GT Ignition switch ez remove and fix. No power but battery good,

So I had a issue. 4 days bike sat then I tried to start, dead but parking lights worked fine. Last night wiggled the cable by ignition switch, nothing , wiggled HARDER with key to on. Bang everything came on. This morning again everything came on, wiggled cable, still worked.
So just about 30 minutes ago I decide to take it apart.

Without removing ANY panels or fairings. Since most the time it's dirty connections I figured I could just disconnect the battery and go for it.

1. Picked off the red paint over screw , used a magnet and jewelers screw drive and removed screw
2. Pulled switch out and put a towel on left side of bike and laid switch on it.
3. Used screw drivers to separate th contacts. Wow like brand new, but cleaned and used dielectric grease and out back together
4. Took wire cover off
Humm all wires looke brand new, and look like connected

5. Pulled slightly on wires, one by one. OPPS, GREEN ONE WAS IN THE HOLE, TOUCHING TAB, BUT PULLED RIGHT OUT, SOLDER HAD FAILED.

6. Clean and then re-soldered - checked again to make sure it held

7. Put cover back on and use small wire tie to hold cable and retainer

8. Put switch back in , screw in, and used blue paint to secure and cover hole.

9. Connect battery, ignition on, ALL GO HOUSTON, THROTTLE FULL OPEN THREE TIMES, SWITCH OFF.

EVERYTHING NORMAL - about 30mins and all is well
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Last edited by Jerrypcman : 05-21-2016 at 02:36 PM. Reason: Pic
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Old 05-22-2016, 05:06 AM
clone5 clone5 is offline
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Re: K1200RS/GT Ignition switch ez remove and fix. No power but battery good,

That little worm screw is ridiculously small
I actually lost the first and had fortunately had a spare.
All the while I was thinking "careful, careful don't drop the screw"
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Old 05-22-2016, 06:01 AM
clone5 clone5 is offline
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Re: K1200RS/GT Ignition switch ez remove and fix. No power but battery good,

I suppose it is actually a blind screw. Anyone know the size? I would like to have a couple in stock
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BMW K1200RS 1997
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Old 05-22-2016, 09:34 AM
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pbegin@burton pbegin@burton is offline
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Re: K1200RS/GT Ignition switch. Clean now...

I went back in after a couple years and over 40,000 miles.And lost the screw....

I had some regular M3? M4? screws.I think size is in the parts fiche. But anyway that's what I used.Had to enlarge the hole in the plastic of the electrical component a little for the screw to go through.A little Loctite and done.

Would make a field repair easy now that the screw is easy to remove.Or if I lose my keys....
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Benelli 50cc at 14
Yamaha RD200 at 16
Yamaha RD350 at 17
Honda CB750F at 18
Honda V45 Sabre at 24
85 BMW K100RS at 28 (Very nice and sorely missed)
90 BMW R100GS at 34 (Too slow, too cranky)
2003 K1200 RS at 53 (Oh Yeah......over 6000RPM)
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