BMW K 1200 LT 1999 Operating instructions

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 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
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
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
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

00.3
Contents - Pre-delivery check Page
Installing the windscreen cover ..............................................................................................35
Checking and adjusting the motorcycle ........................................................................35
Checking the function of side stand contact switch .....................................................35
Adjusting the seat .........................................................................................................................35
Adjusting the top case ................................................................................................................35
Checking headlight beam angle, adjusting if necessary .............................................36
Vertical adjustment ............................................................................................................................36
Lateral adjustment .............................................................................................................................36
Final inspection and function check ...............................................................................37
Final cleaning ................................................................................................................................37

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

00.7
00
Tightening torques
Model K 1200 LT
Connection Nm
11 Engine
Cylinder head
Cylinder head bolts
Joint torque 20 Oiled before installation
Wrench angle 90°
Cylinder head cover 9
Heat shield for cylinder-head cover 5
Coolant stub pipe 9
Intake stub pipe 9
Split conrods
Split-conrod bearing 20
Wrench angle 80°
Crankshaft
Rotor flange 50
Main bearing 50
Cover, crankcase 9
Freewheel
Cover plate 10
Engine block
Collared bearing, output shaft 40
Needle bearing, output shaft 20
Lower section of crankcase 10
Oil sump 10
Oil drain plug 30
Oil filter cover 10
Oil filter 11
Oil mesh strainer 10

00.8
11 Engine
Camshafts
Bearing cap 10
Chain sprockets 56
Intermediate flange
Thrust plate, driver to intermediate flange 9 (clean thread + Loctite 243)
Driver to auxiliary shaft 50
Intermediate flange to engine block 9
Timing case
Chain tensioner to cover of timing case 9
Screw plug for chain tensioner 9
Timing case cover 9
Oil/water pump
Water-pump impeller to pump shaft 33
Water-pump temperature sensor 9
Oil pressure switch 35
Oil pressure relief valve screw plug 35
Pump housing to crankcase 10
Cover, pump housing 10
Model K 1200 LT
Connection Nm

00.9
12 Engine electrics
Spark plugs 20
Ignition coil
Ignition coil to mounting plate 8
Mounting plate to intermediate flange 9
Cover, shield housing 5
Ignition signal sensor
Rotor 4
Magnetic gate 6
Cover, ignition sensor 9
Alternator
Mount to intermediate flange 20
Driver housing to alternator shaft 50
Connector, lead B+ 10
Connector, lead D+ 2
Starter motor
Starter motor to gearbox 6
Pinch bolt, starter-motor housing 6
Positive lead to starter motor 6
Earth (ground) lead to cross-tube 6
13 Fuel preparation and control
Air intake connection to cylinder head 9
Hose clips Hand-tight
Fuel lines to engine 9
Injection rail to cylinder head 9
Retaining plate for cruise control system to
fairing bracket 8
Throttle-valve actuator to throttle-valve rail 5 (clean thread + Loctite 270)
Throttle-valve potentiometer to throttle-
valve rail 2
Temperature sensor to intake air silencer 15
Model K 1200 LT
Connection Nm

00.10
16 Fuel tank and lines
Union nut, fuel-pump unit 30
Roll-over valve 3
Immersion-tube sensor 6
Fuel tank to frame M 8 21
Bridge to frame M 8 21
Bridge to frame M 6 9
17 Radiator
Hose clips Hand-tight
Fan to radiator 2 (clean thread + Loctite 2701)
Water pump temperature sensor 9
Coolant stub pipe to cylinder head 9
18 Exhaust system
Oxygen sensor to exhaust system 45
Exhaust system to cylinder head 22
Exhaust mountings
Retaining plate to pivot mount 41
Stirrup to retaining plate 30 (clean thread + Loctite 243)
Stirrup to silencer 21
Model K 1200 LT
Connection Nm

00.11
21 Clutch
Clutch-lever fitting to handlebar 5
Grub screw in filler adapter 10
Filler adapter to breather line 18 (clean thread + Loctite 243)
Clutch housing to output shaft
initial torque
release
second torque
wrench angle 60°
140
50
Cover to clutch housing 18
Lines to clutch slave cylinder 7
Clutch slave cylinder to gearbox 9
Pressure line to clutch fitting 18
Connector, pressure line 10
23 Transmission
Oil drain plug 55
Oil filler plug 30
Speed sensor for reverser to gearbox
housing 6
Housing cover to housing 9
Gearshift linkage
Selector lever to selector shaft 9
Relay lever to transverse tube 9
Ball head to gearshift pedal 8 (clean thread + Loctite 2701)
Gearbox mounts
Gearbox to intermediate flange 24
Clamp, rubber mount 9
Gearbox to frame 70
Reverser
Link from actuator for reverser to
intermediate flange 24 (clean thread + Loctite 243)
Actuator, reverser to link 24 (clean thread + Loctite 243)
Reverse gear switch to actuating shaft 9
Switch unit, reverser to gearbox 9
Actuator lever, reverser 6 (clean thread + Loctite 243)
Cover, reverser to gearbox housing 10
Cover plate, reverser 10 (clean thread + Loctite 243)
Threaded pin M 6 in cover, reverser 5 (clean thread + Loctite 243)
Model K 1200 LT
Connection Nm

00.12
31 Front forks
Fork bridge to frame
(nut micro-encapsulated) 130 (clean thread + new nut or Loctite 2701)
Fork stanchion to fork bridge 45
Steering damper to slider tube bridge
(screw micro-encapsulated) 21 (clean thread + new screw or Loctite 243)
Steering damper to leading link 21 (clean thread + new screw or Loctite 243)
Leading link to fork slider bridge
(nut micro-encapsulated) 130 (clean thread + Loctite 2701)
Ball joint to fork slider bridge 230
Leading link to fork slider bridge 130 (clean thread + Loctite 2701)
Leading link to frame 107 (clean thread + Loctite 243)
Clamp, leading link M 8 21
Spring strut to leading link 43
Suspension strut to frame 43
Slider tube bridge to slider tube 21 (clean thread + new screw or Loctite 243)
Brake distributor to holder, sliding tube right 9
Oil drain plug in slider tube 12
Vent screw, stanchion 3
32 Steering
Brake-lever fitting to handlebar 5
Clutch-lever fitting to handlebar 5
Handlebar to fork bridge 21
Bearing screw, brake and clutch levers 5 (clean thread + Loctite 2701)
Model K 1200 LT
Connection Nm