BMW K 1200 LT 1999 Betriebsanleitung

BMW AG Motorcycle Division

After Sales

K 1200 LT

Repair Manual

Published by: © BMW AG Motorcycle Division

After Sales

UX-VS-2

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 illus-

trations.

If the work described here is restricted to a particular equipment specification, for instance if a specific op-

tional 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

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

LNote:

Specific information on operating, inspecting and adjusting work for the motorcycle as well as maintenance

procedures.

eCaution:

Instructions and precautions specifically intended to prevent damage to the motorcycle. Failure to comply

with them could invalidate the warranty.

dCaution:

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

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

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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