BMW K 1200 LT Betriebsanleitung

BMW AG Motorcycle Division

After Sales

K 1200 LT

Repair Manual

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

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:

–Conditionoftiresandwheels,tyrepressure

– Clutch, gearshift mechanism, hand and foot brake, ABS, steering system

–Lightingandsignallingequipment,telltalelights,instruments,horn

–Reversingaid,radiowithremotecontro,optionalequipmentfitted

– Trial run if necessary

*)Charged as an additional item

BMW AG Motorcycle Division

Maintenance schedule

K 1200 LT

00.4

Contents - Maintenance Page

Key to maintenance intervals ..............................................................................................38

General instructions .................................................................................................................39

Pushing the motorcycle onto a workshop platform .......................................................39

High idle speed ..............................................................................................................................39

Removing the aerial .....................................................................................................................39

Reading the fault code memory with the MoDiTeC ................................................40

(Inspections I, II, III and IV) .................................................................................................................40

Checking throttle cable play, adjusting if necessary .............................................40

(Inspections I and III) .........................................................................................................................40

Models without cruise control .................................................................................................40

Models with cruise control ........................................................................................................40

Throttle-opener cable, throttle-closer cable ......................................................................................40

Cruise-control system cable ..............................................................................................................41

Turning the throttle twist grip relative to the throttle valve shaft ..............................41

Cruise control system does not switch off .........................................................................................41

Cruise control system cannot be set, or continually shuts down .......................................................41

Changing engine oil, replacing oil filter element ......................................................42

(Inspections I, II, III and IV) .................................................................................................................42

Changing gearbox oil ...............................................................................................................43

Change the gearbox oil every two years at the latest .........................................................................43

(Inspection III) ....................................................................................................................................43

Changing the oil in the rear wheel drive ........................................................................44

Change the oil in the rear wheel drive every two years at the latest ...................................................44

(Inspections I and III) .........................................................................................................................44

Brake pads/brake discs ..........................................................................................................45

Checking brake pads and discs for wear and replacing if necessary .................................................45

(Inspections II and III) .........................................................................................................................45

Checking brake pads for wear ................................................................................................45

Front brake pads ...............................................................................................................................45

Rear brake pads ................................................................................................................................45

Replacing brake pads .................................................................................................................46

Front brake ........................................................................................................................................46

Rear brake ........................................................................................................................................47

Checking the brake discs .........................................................................................................48

Maintenance

00.5

Contents - Maintenance Page

Checking the front/rear brake fluid level ......................................................................48

(Inspections I, II and III) ......................................................................................................................48

Checking the front brake fluid level ......................................................................................48

Checking the fluid level with brake fluid

reservoir open ...................................................................................................................................49

Checking the rear brake fluid level ........................................................................................50

(Inspections I, II and III) ......................................................................................................................50

Checking operation of brake system and freedom from leaks, repairing/repla-

cing if necessary ............................................................................................................................50

(Inspection III) ....................................................................................................................................50

Changing brake fluid and bleeding brake system ...................................................51

Change the brake fluid once a year at the latest ................................................................................51

(Inspection IV) ....................................................................................................................................51

Front brake .......................................................................................................................................51

Forcing back the brake pistons .........................................................................................................51

Opening the brake fluid reservoir .......................................................................................................51

Bleeding the front brake pressure modulator ....................................................................................52

Bleeding the left brake calliper ..........................................................................................................52

Bleeding the front right brake calliper ................................................................................................53

Rear brake ........................................................................................................................................54

Bleeding the rear brake pressure modulator .....................................................................................54

Forcing back the brake pistons .........................................................................................................54

Bleeding the brake calliper ................................................................................................................55

Checking clutch fluid level ....................................................................................................55

(Inspections I, II and III) ......................................................................................................................55

Changing the clutch fluid (every 40,000 km/24,000 miles) ..................................56

Change the clutch fluid every 2 years at the

latest .................................................................................................................................................56

(Inspection III) ....................................................................................................................................56

Replacing fuel filter (every 40,000 km/24,000 miles) ...............................................58

(Inspection III) ....................................................................................................................................58

Removing the fuel pump unit ...................................................................................................58

Removing and installing fuel filter ..........................................................................................59

Installing the fuel-pump unit .....................................................................................................59

Checking and topping up, if necessary, coolant level and concentration .60

(Inspections I and III) .........................................................................................................................60

Changing coolant .......................................................................................................................61

(Inspection IV) ....................................................................................................................................61

Draining coolant .............................................................................................................................61

Filling coolant system ..................................................................................................................62

00.6

Contents - Maintenance Page

Battery ..............................................................................................................................................63

(Inspections III and IV) .......................................................................................................................63

Check battery acid level and add distilled water if necessary; inspect battery terminals and clean and

grease them if necessary ..................................................................................................................63

Checking battery acid level ......................................................................................................63

Adding distilled water ..................................................................................................................63

Installing the battery .....................................................................................................................63

Replacing intake air filter element ....................................................................................64

(Inspection III) ....................................................................................................................................64

Checking function of side stand contact switch ......................................................64

(Inspections I, II and III) ......................................................................................................................64

Greasing the side stand ..........................................................................................................65

(Inspections II, III and IV) ....................................................................................................................65

Checking the centre stand, greasing if necessary ..................................................65

(Inspections II, III and IV) ....................................................................................................................65

Checking the centre stand .......................................................................................................65

Greasing the centre stand ........................................................................................................65

Checking the steering damper ...........................................................................................67

(Inspections II and III) .........................................................................................................................67

Checking tightness of rear wheel studs ........................................................................67

(Inspection I) ......................................................................................................................................67

Checking rear wheel bearing play by tilting wheel ..................................................67

(Inspection III) ....................................................................................................................................67

Checking swinging arm bearings, adjusting if necessary ...................................67

(Inspections I and III) .........................................................................................................................67

Cleaning the inductive sensor on the rear wheel (every 40,000 km/

24,000 miles) .................................................................................................................................67

Clean the inductive sensor on the rear wheel every two years at the latest .......................................67

(Inspection III) ....................................................................................................................................67

Checking valve clearances, adjusting if necessary ................................................68

(Inspection III) ....................................................................................................................................68

Checking valve clearances .......................................................................................................68

Adjusting valve clearances .......................................................................................................68

Replacing the chain tensioning rail lining and chain guide rail ........................70

(every 60,000 km/36,000 miles) ........................................................................................................70

Replacing spark plugs .............................................................................................................71

(Inspection III) ....................................................................................................................................71

Final inspection with road safety and functional check .......................................71

(Inspections I, II, III and IV) .................................................................................................................71

00.45

Brake pads/brake discs

Checking brake pads and discs for wear and

replacing if necessary

(Inspections II and III)

Checking brake pads for wear

dWarning:

Never permit brake pads to wear past minimum per-

missible thickness.

Always replace pads as a complete set.

Front brake pads

eCaution:

Do not scrape the wheel – mask it off if necessary.

–Removethebrakecalliper.

•Measure brake pad thickness (arrows).

Minimum pad thickness .............. 1.0 mm (0.04 in)

XTightening torques:

Brake calliper to fork tube ............................ 40 Nm

Rear brake pads

•Release the brake line from the clips (arrows) on

the rear-wheel drive.

•Release fasteners (1, 2), remove brake calliper.

•Measure brake pad thickness (arrows).

Minimum pad thickness .............. 1.0 mm (0.04 in)

XTightening torques:

Brake calliper to rear wheel drive ................. 40 Nm

KR340240

KL000060

KL000160

11.11

Cutaway drawing of engine, K 1200 LT

KL119000

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