BMW Motorcycle K1200LT Repair Manual

[Martin Welker]

Download this document, you need 500 Gallons

BMW Motorcycle K1200LT Repair Manual
Size: 39.88 MB
Format: PDF
Language: English
Brand: BMW
Type of Machine: Motorcycle
Type of Manual: Repair Manual
Model: BMW K1200LT Motorcycle
Number of Pages: 452 Pages

Contents:
Repair Manual
Introduction
U sage
Key to symbols
Contents
Activities
Contents
Maintenance schedule
Pre-delivery check
00 Maintenance and general instructions
Tightening torques
Table of operating fluids
Overview: K1200LT packing materials
Checking the shipping crate for damage
Damage discovered in Germany
Damage discovered in importer markets
Unpacking the motorcycle
Installing the front wheel
General instructions
Pushing the motorcycle onto a workshop platform
Inspecting motorcycle for damage
Checking that delivery is complete
Installing remaining items on motorcycle
Installing the front mudguard
Installing the mirrors
Installing the footrests
Installing the engine spoilers
Installing the reverser control
Installing the skirts
Installing the top case
Filling and charging the battery
Checking brake fluid level
Front brake
Rear brake
Checking clutch fluid level
Checking tyre pressures
Checking tightness of rear wheel studs
Installing the aerial
Installing the windscreen
Installing the windscreen cover
Checking and adjusting the motorcycle
Checking the function of side stand contact switch
Adjusting the seat
Adjusting the top case
Checking headlight beam angle, adjusting if necess
Final inspection and function check
Final cleaning
Key to maintenance intervals
General instructions
Pushing the motorcycle onto a workshop platform
High idle speed
Removing the aerial
Reading the fault code memory with the MoDiTeC
(Inspections I, II, III and IV)
Checking throttle cable play, adjusting if necess
(Inspections I and III)
Models without cruise control
Models with cruise control
Turning the throttle twist grip relative to the th
Changing engine oil, replacing oil filter element
(Inspections I, II, III and IV)
Changing gearbox oil
Change the gearbox oil every two years at the late
(Inspection III)
Changing the oil in the rear wheel drive
Change the oil in the rear wheel drive every two y
(Inspections I and III)
Brake pads/brake discs
Checking brake pads and discs for wear and replaci
(Inspections II and III)
Checking brake pads for wear
Replacing brake pads
Checking the brake discs
Checking the front/rear brake fluid level
(Inspections I, II and III)
Checking the front brake fluid level
Checking the rear brake fluid level
Checking operation of brake system and freedom fro
Changing brake fluid and bleeding brake system
Change the brake fluid once a year at the latest
(Inspection IV)
Front brake
Rear brake
Checking clutch fluid level
(Inspections I, II and III)
Changing the clutch fluid (every 40,000 km/24,00
Change the clutch fluid every 2 years at the lates
(Inspection III)
Replacing fuel filter (every 40,000 km/24,000 mile
(Inspection III)
Removing the fuel pump unit
Removing and installing fuel filter
Installing the fuel-pump unit
Checking and topping up, if necessary, coolant le
(Inspections I and III)
Changing coolant
(Inspection IV)
Draining coolant
Filling coolant system
Battery
(Inspections III and IV)
Check battery acid level and add distilled water i
Checking battery acid level
Adding distilled water
Installing the battery
Replacing intake air filter element
(Inspection III)
Checking function of side stand contact switch
(Inspections I, II and III)
Greasing the side stand
(Inspections II, III and IV)
Checking the centre stand, greasing if necessary
(Inspections II, III and IV)
Checking the centre stand
Greasing the centre stand
Checking the steering damper
(Inspections II and III)
Checking tightness of rear wheel studs
(Inspection I)
Checking rear wheel bearing play by tilting wheel
(Inspection III)
Checking swinging arm bearings, adjusting if neces
(Inspections I and III)
Cleaning the inductive sensor on the rear wheel (e
Clean the inductive sensor on the rear wheel every
(Inspection III)
Checking valve clearances, adjusting if necessary
(Inspection III)
Checking valve clearances
Adjusting valve clearances
Replacing the chain tensioning rail lining and cha
(every 60,000 km/36,000 miles)
Replacing spark plugs
(Inspection III)
Final inspection with road safety and functional c
(Inspections I, II, III and IV)
11 Motor
Cutaway drawing of engine, K 1200 LT
Preparatory work with engine installed
…for removal of combined oil/water pump
…for removal of timing case cover, removal of timi
for removal of cylinder head
Removing/installing engine
Removing engine
Installing engine
Disassembling engine
Removing, disassembling/assembling water pump
Removing timing chain cover
Removing the timing chain
Removing, disassembling and assembling cylinder h
Removing/installing crankshaft gear and rotor flan
Removing crankshaft
Removing, disassembling and assembling piston with
Measure backlash at the countershaft
Removing intermediate flange
Disassembling/assembling intermediate flange
Removing countershaft and layshaft with freewheel
Disassembling/assembling freewheel
Removing/installing needle bearing for layshaft an
Removing output shaft
Disassembling/reassembling output shaft
Assembling engine
Installing output shaft
Installing intermediate flange
Installing crankshaft
Measuring crankshaft bearing play
Installing piston with conrod
Installing big end bearing
Measuring big end bearing play
Checking dimensions of crankshaft
Installing cylinder head
Installing camshafts
Installing timing chain
Installing timing case cover
Checking valve clearances
Adjusting valve clearances
Installing ignition pulse generator
Installing combined oil/water pump
Installing crankcase cover
Installing cylinder head cover
12 Engine electrics
Removing and installing Hall-effect transmitters
Preparatory work
Removing cover from Hall-effect transmitter
Removing magnetic gate
Installing the magnetic gate
Installing the cover of the Hall-effect transmitte
Replacing spark plugs/ignition leads
Removing and installing spark plugs
Removing and installing ignition leads
Removing and installing coil
Motorcycles without shield housing
Motorcycles with shield housing
Timing the ignition
Preparatory work
Setting timing with Motronic
Setting timing without Motronic
Replacing three-phase generator
Removing and installing three-phase generator
Disassembling the three-phase generator
Replacing starter motor
Removing and installing starter motor
Disassembling/assembling starter motor
13 Fuel preparation and control
Removing and installing Motronic control unit
Replacing intake air filter element
See Group 00
Replacing air temperature sensor
Removing and installing intake air silencer
Removing and installing fuel injection rail
Removing and installing injectors
Removing and installing pressure regulator
Removing and installing throttle valve rail
Removing and installing throttle valve actuator
Replacing and adjusting throttle valve potentiomet
Removing and installing intake stubs
Replacing fuel hoses
Removing and installing throttle cables
Preparatory work for all Bowden cables
Removing and installing throttle- opener and throt
Removing and installing Bowden cable of cruise-con
Checking fuel pressure
Removing and installing control unit of cruise-con
See Group 65
Checking throttle cable play, adjusting if necess
See Group 00
16 Fuel tank and lines
Removing and installing fuel tank
Renewing fuel filter
Removing the fuel pump unit
Removing/installing fuel filter
Removing/installing fuel pump
Installing the fuel-pump unit
Removing/installing immersion-tube sensor
Calibrating the immersion-tube sensor
Removing/installing roll-over valve
17 Radiator
Coolant circuit
Removing and installing coolant hoses
Connecting hose between left and right radiators
Hoses between radiators and coolant stub pipes
Hose between coolant stub pipes
Coolant hose to water pump
Removing breather hose
Vapour outlet hose
Changing coolant
See Group 00
Checking cooling system for leaks
Removing and installing radiator with fan
Removing and installing left radiator
Removing and installing right radiator
Removing and installing coolant stub pipe on engin
Removing and installing thermostat
Troubleshooting
18 Exhaust system
Removing and installing exhaust heat shield
Removing and installing exhaust system
Removing oxygen sensor
21 Clutch
Removing and installing clutch
Preparatory work
Removing clutch
Removing clutch housing
Installing clutch housing
Installing clutch
Changing the clutch fluid/bleeding the clutch syst
Removing and installing clutch lines
Removing and installing vent line
Removing and installing clutch pressure line
Removing and installing clutch slave cylinder
Removing and installing clutch release rod
23 Gearbox
Gearbox – sectional drawing
Replacing the shaft sealing rings in the gearbox h
Replacing input shaft sealing ring at input side
Replacing output shaft sealing ring
Replacing shaft sealing ring for selector shaft o
Replacing input shaft sealing ring at output side
Replacing shaft sealing ring for selector drum
Replacing shaft sealing ring for selector shaft
Removing and installing actuating unit for reverse
Removing and installing actuating control for reve
Removing and installing actuating unit for reverse
Disassembling/assembling double switch for reverse
Removing gearbox
Disassembling gearbox
Preparatory work
Disassembling reverser gear train
Removing gearbox housing
Removing selector drum
Disassembling/assembling selector shaft
Removing gearbox shafts
Replacing grooved ball bearing on intermediate sha
Disassembling/assembling input shaft
Disassembling/assembling output shaft
Checking endplay
Checking/adjusting fully assembled length of gearb
Assembling gearbox
Installing gearbox shafts
Installing gearbox housing
Installing reverser
Completing assembly of gearbox
Installing gearbox
Removing and installing gearshift lever and linkag
Removing and installing gearshift lever
Aligning rubber mounts
Aligning left-hand rubber mount
Aligning right-hand rubber mount
31 Front fork
Removing and installing telescopic forks and fork
Removing telescopic fork
Removing fork bridge
Disassembling fork bridge
Installing fork bridge
Installing telescopic fork
Assembly specification for telescopic fork
Disassembling/assembling telescopic fork leg
Disassembling telescopic fork leg
Assembling telescopic fork leg
Measuring telescopic fork
Examining slider tube bridge and fork bridge
Checking runout of fixed tube
Checking runout of slider tube
Removing and installing slider tube bridge
Removing and installing ball joint
Removing and installing front suspension strut
Removing front suspension strut
Installing suspension strut
Removing and installing steering damper
Checking the steering damper
Removing and installing leading link
Removing leading link
Removing left angular-contact ball bearing for lea
Installing left angular-contact ball bearing for l
Installing leading link
Measuring the leading link
32 Steering
Removing and installing left grip tube
Removing and installing right grip tube
Removing and installing clutch lever fitting
Removing and installing brake lever fitting
Removing and installing handlebar
Installation instructions for adjusting handlebar
Removing and installing piston in brake-lever fitt
Adjusting lever play for front brake/ clutch
Removing and installing left and right handlebar l
Removing and installing throttle cables
See Group 13
33 Rear wheel drive
Rear wheel drive – cutaway drawing
Removing, disassembling, reassembling and install
Removing rear wheel drive
Replacing taper roller bearing in rear wheel drive
Removing input bevel pinion
Disassembling input bevel pinion
Assembling input bevel pinion
Installing input bevel pinion
Removing crown wheel
Installing crown wheel
Checking/adjusting backlash
Checking tooth contact pattern
Shimming housing cover
Installing housing cover
Installing rear drive shaft
Installing rear wheel drive
Removing, disassembling, reassembling and install
Removing rear swinging arm
Removing and installing flexible gaiter
Removing and installing threaded ring bearings
Removing drive shaft
Installing drive shaft
Installing rear swinging arm
Removing and installing suspension strut
34 Brakes
Front brake calliper
Removing and installing front brake calliper
Removing and installing filler adapter
Removing and installing front brake pistons
Rear brake calliper
Removing and installing rear brake calliper
Removing and installing rear brake pistons
Removing and installing front brake disc
Removing and installing rear brake disc
Removing and installing front ABS sensor
Removing front ABS sensor ring
Adjusting front ABS sensor
Marking the ABS sensor ring
Checking/adjusting ABS sensor gap
Removing and installing rear ABS sensor
Adjusting rear ABS sensor
Marking the ABS sensor ring
Checking/adjusting ABS sensor gap
Removing and installing rear brake master cylinder
Checking/adjusting play at piston rod
Checking play at piston rod
Adjusting play at piston rod
Removing and installing ABS control unit
Removing and installing ABS relay
Removing and installing front brake lines/hoses
Removing front brake lines/hoses
Installing front brake lines/hoses
Removing and installing rear brake lines/hoses
Removing brake lines/hoses
Installing brake lines/hoses
Checking brake pads for wear/ replacing brake pads
See Group 00
Checking brake fluid level
See Group 00
Replacing brake fluid and bleeding brake system
See Group 00
36 Wheels and tyres
Removing and installing front wheel
Removing and installing wheel bearings
Removing left/right wheel bearings
Installing right/left wheel bearing
Removing/installing rear wheel
Removing rear wheel
Installing rear wheel
Static balancing of front and rear wheels
Static balancing of front wheel
Static balancing of rear wheel
Checking front/rear wheel rim for run-out
Checking front wheel rim for run-out
Checking rear wheel rim for run-out
46 Frame
Overview of fairing sections, K 1200 LT
Removing and installing fairing side section
Removing and installing mirror
Removing and installing fin
Removing and installing front turn indicator
Removing and installing bottom of tank cover
Removing and installing fairing skirt
Removing skirt
Removing and installing fairing side section
Removing and installing tank cover
Removing flap of radio compartment
Removing and installing engine spoiler
Removing/installing components mounted on side sec
Removing air outlet duct
Removing kneepad
Removing grille
Removing badge
Removing rubber stop for radio cover
Removing and installing battery cover
Removing windscreen
Removing windscreen cover
Removing windscreen
Removing and installing windscreen adjuster
Removing and installing instrument cover
Removing and installing upper section of fairing
Removing and installing left/right handlebar trim
Removing and installing fork bridge cover
Removing/installing interior trim
Removing and installing left/right wind deflectors
Removing and installing front mudguard
Removing and installing front mudguard front sect
Removing and installing front mudguard rear secti
Removing and installing front footrests
Removing and installing front right footrest plate
Removing and installing front left footrest plate
Removing gearshift lever
Removing and installing left/right rear footrest p
Removing and installing rear footrests
Disassembling rear footrest
Disassembling and assembling side stand
Removing and installing main (centre) stand
See Group 00, Lubricating main stand
Removing and installing intake air pipe
Removing and installing skirt bracket
Removing and installing crash bar
Removing and installing radiator holder
Removing and installing rear- mounted components
Removing and installing number-plate carrier
Removing and installing top case
Disassembling top case
Removing and installing rear carrier cover
Removing and installing case trimmer
Removing and installing side case
Removing and installing side case lid
Removing and installing rear moulding
Removing and installing rear carrier section
Removing rear mudguard
Removing and installing front fairing bracket
Removing reflectors
Removing and installing retaining plates in front
Checking running gear
Measuring wheel track offset
Checking the leading link for deformation
Removing and installing frame
Removing and installing rear frame
Removing and installing cross-tube
Removing and installing left/right engine cross-me
Removing main frame
Installing main frame
51 Equipment
Removing and installing ignition switch/steering l
Removing and installing lock barrel
Disassembling/assembling fuel tank lock
Removing and installing flap for tank cap
Removing and installing snap lock for tank cap fla
Removing and installing fuel tank lock barrel
Removing and installing lock barrel of fuel tank c
Removing and installing locking system for front s
Removing locking system
Removing and installing Bowden release cable
Removing and installing lock barrel of side case
Removing and installing lock barrel of top case
52 Seat
Removing and installing seat
Removing and installing front seat with bridge
Removing and installing rear seat
Removing and installing rear seat backrest
Disassembling/assembling front seat
Removing and installing front seat
Removing and installing gas-filled strut
61 General electrical equipment
Wiring harness
View from right
View from left
Rear frame wiring harness
Top case wiring
Tank cover with radio/cassette player
Connectors beside ABS control unit
Connectors on fairing bracket
Relay positions in electronics box
Connectors, electronics box
Handlebar wiring
Replacing fuses
Motorcycle fuses
Fuses
Fuse for radio/cassette player
Removing and installing electronics box
Disassembling left multi-function switch
Preparatory work
Removing and installing radio control unit
Removing and installing clutch switch
Removing left multi-function switch
Disassembling right multi-function switch
Removing and installing right multi-function switc
Removing brake light switch
Removing and installing control unit for reverser
Removing and installing inductive sensor for speed
Removing and installing water temperature sensor
Replacing side stand switch
Removing and installing side stand switch
Check operation of side stand switch
Replacing and adjusting foot brake light switch
Removing and installing brake light switch
Adjusting brake light switch
Removing and installing ignition switch/steering l
Removing and installing fanfare horn
Removing and installing switch for gear indicator
Removing and installing power socket
Socket on engine spoiler
Socket in top case
Removing and installing cable for oil pressure swi
Removing cables
Installing cables
Removing and installing battery
See Group 00, Battery
Removing and installing battery carrier
See Group 34, Removing ABS control unit
Removing and installing front and rear ABS sensors
See Group 34
62 Instruments
Wiring colours
Removing and installing instrument panel
Replacing telltale/warning lights
Telltale/warning lights
Disassembling instrument cluster
Removing speedometer, rev. counter, temperature ga
Removing clock
Removing and installing wiring harness
63 Lights
Removing and installing headlight
Renewing bulbs
Bulb for low-beam headlight/ high-beam headlight
Bulb, parking light
Front turn signal
Rear lights
Checking headlight beam angle, adjusting if necess
Vertical adjustment
Lateral adjustment
65 Radio and optional extras
Removing and installing speakers
Front speakers
Rear speakers
Removing and installing radio/ cassette player
Preparatory work
Removing radio control unit
Removing radio/cassette player and wiring harness
Removing and installing radio remote control unit
Removing and installing front radio remote control
Removing and installing rear radio remote control
Removing and installing aerial holder
Removing and installing on-board computer
Removing and installing temperature sensor on upp
Removing and installing control unit of cruise-con