1997-2004 BMW K1200 K12000LT Motorcycle Service & Repair Manual

BMW AG Motorcycle Division After Sales K 1200 LT Repair Manual

Published by: © BMW AG Motorcycle Division 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. Produced in Germany 7/99

Introduction This repair manual will help you to perform all the main maintenance and repair work correctly and efficient- ly. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and prac- tical knowledge acquired at the BMW Training Centre. It is a contribution towards achieving even higher 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 An arrow symbol followed by the chapter and page numbers is a reference to another chapter, e.g. Ób ............................................ See Group 46 • 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 (ETC), 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 (OE) is fitted, this is stated in square brackets at the start of the item concerned, e.g. [With heat- ed handlebar grips]. Please refer to the following pages as well for a description of other symbols used and how to work with it. BMW AG Motorcycle Division After Sales Published by: BMW AG Sparte 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

Usage Each chapter starts with the list of contents. The list of contents is followed by the Technical Data table. Chapter 00 “Maintenance and general instructions” details the handover checklist and lists all tightening torques and operating fluids. Key to symbols In this Workshop Manual for the K 1200 LT model, the following symbols are used; their meanings are ex- plained in the table. Special instructions aimed at improving the work procedures L Note: Specific information on operating, inspecting and adjusting work for the motorcycle as well as maintenance procedures. e Caution: Instructions and precautions specifically intended to prevent damage to the motorcycle. Failure to comply with them could invalidate the warranty. d Caution: 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 Headlines for the work described in the chapter........................................... with the relevant page number 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 “release” 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 X Tightening torques: Values are stated if they differ from DIN EN 24 014 or DIN 912 ISO industrial standards.

00 Maintenance and general instructions 00.1 11 Motor 11.1 12 Engine electrics 12.1 13 Fuel preparation and control 13.1 16 Fuel tank and lines 16.1 17 Radiator 17.1 18 Exhaust system 18.1 21 Clutch 21.1 23 Gearbox 23.1 31 Front fork 31.1 32 Steering 32.1 Contents Group / Chapter

33 Rear wheel drive 33.1 34 Brakes 34.1 36 Wheels and tyres 36.1 46 Frame 46.1 51 Equipment 51.1 52 Seat 52.1 61 General electrical equipment 61.1 62 Instruments 62.1 63 Lights 63.1 65 Radio and optional extras 65.1 Group / Chapter

Order No. 01 71 9 799 278 UX-VS-2, 01/99 Printed in Germany Customer Licence plate No. Order No. Mechanic’s signature BMW Inspection at 1,000 km (600 miles) BMW Service every 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 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 * ) every 2 years Change oil in rear wheel drive while at operating temperature at least every 2 years * ) every 2 years Examine brake pads and discs for wear, replace if necessary * ) Check the front/rear brake fluid level Check operation of brake system and freedom from leaks; repair/replace items if necessary * ) Replace the brake fluid at least once a year Check clutch operating fluid level Change clutch fluid every 40,000 km (24,000 miles) or at least every 2 years * ) 40,000 every 2 years 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 and top up, where necessary, coolant level and concentration Replace the coolant at least every 2 years* ) every 2 years 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 * ) Clean the inductive sensor on the rear wheel every 40,000 km (24,000 miles) or at least every 2 years * ) 40,000 every 2 years Check valve clearances, adjust if necessary Replace the lining of the chain tensioning rail and chain guide rail 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, ABS, steering system – Lighting and signalling equipment, telltale lights, instruments, horn – Reversing aid, radio with remote contro, optional equipment fitted – Trial run if necessary * ) Charged as an additional item BMW AG Motorcycle Division Maintenance schedule K 1200 LT

Order No. 01 71 9 799 278 UX-VS-2, 01/99 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 Top case lock cylinder Toolkit and helmet lock Documentation Top case (packed separately) Optional extras Installing remaining items on motorcycle – Fit front wheel and mudguard – Fit the mirror – Fit the right-hand side footrest and passenger footrest plate – Fit engine spoiler, reversing aid actuation, bumpers – Install the top case Fill and charge the battery (mark with charging date) Check the front/rear brake fluid level Check clutch fluid level Check tyre pressures Check rear wheel studs for tightness (note correct tightening torque) Fit antenna, windshield Checking and adjusting the motorcycle – Check function of side stand contact switch – Seat – Top case – Headlight, spring strut Add fuel Final inspection and function check – Check engine oil when engine is cold – Clutch, gearshift mechanism, reversing aid – Lighting and signalling equipment, telltale lights, instruments – Check radio for operation – Hand brake and foot brake, ABS – Check optional equipment for operation CD player, on-board computer, cruise control – Trial run if necessary Confirm pre-delivery check in Service and Technical Booklet Final cleaning Motorcycle handed over on: BMW AG Motorcycle Division Pre-delivery check K 1200 LT

00.1 Contents Page 00 Tightening torques ......................................................................................................................7 Table of operating fluids ......................................................................................................... 19 00 Maintenance and general instructions Tightening torques and Table of operating fluids Pre-delivery check Maintenance

00.2 Contents - Pre-delivery check Page Overview: K1200LT packing materials ........................................................................... 21 Checking the shipping crate for damage ..................................................................... 22 Damage discovered in Germany ............................................................................................ 22 Damage discovered in importer markets ........................................................................... 22 Unpacking the motorcycle .................................................................................................... 23 Installing the front wheel ....................................................................................................... 24 General instructions ................................................................................................................. 26 Pushing the motorcycle onto a workshop platform ....................................................... 26 Inspecting motorcycle for damage .................................................................................. 26 Checking that delivery is complete .................................................................................. 26 Installing remaining items on motorcycle .................................................................... 27 Installing the front mudguard ................................................................................................... 27 Installing the mirrors .................................................................................................................... 27 Installing the footrests ................................................................................................................. 28 Installing the rear left footrest plate .................................................................................................... 28 Installing the rear right footrest and footrest plate ............................................................................. 28 Installing the engine spoilers ................................................................................................... 29 Installing the reverser control .................................................................................................. 29 Installing the skirts ........................................................................................................................ 29 Installing the top case ................................................................................................................. 30 Additional instructions for moving the backrest ................................................................................. 30 Filling and charging the battery ......................................................................................... 31 Checking brake fluid level ..................................................................................................... 32 Front brake ....................................................................................................................................... 32 Rear brake ........................................................................................................................................ 33 Checking clutch fluid level .................................................................................................... 34 Checking tyre pressures ........................................................................................................ 34 Checking tightness of rear wheel studs ........................................................................ 34 Installing the aerial .................................................................................................................... 34 Installing the windscreen ....................................................................................................... 35 Pre-delivery check

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1997-2004 BMW K1200 K12000LT Motorcycle Service & Repair Manual

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