BMW K 1200 LT Operating instructions

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
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

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
1
2
KL000160

11.11
Cutaway drawing of engine, K 1200 LT
KL119000

12.1
Contents Page
12
Technical Data ............................................................................................................................... 3
Removing and installing Hall-effect transmitters .......................................................5
Preparatory work .............................................................................................................................5
Removing cover from Hall-effect transmitter ......................................................................5
Removing magnetic gate .............................................................................................................5
Installing the magnetic gate .......................................................................................................6
Installing the cover of the Hall-effect transmitter ..............................................................6
Replacing spark plugs/ignition leads ................................................................................7
Removing and installing spark plugs .....................................................................................7
Removing and installing ignition leads ..................................................................................7
Removing and installing coil ..................................................................................................8
Motorcycles without shield housing .......................................................................................8
Motorcycles with shield housing ..............................................................................................9
Timing the ignition .......................................................................................................................9
Preparatory work .............................................................................................................................9
Setting timing with Motronic ....................................................................................................10
Setting timing without Motronic ..............................................................................................10
Replacing three-phase generator .....................................................................................11
Removing and installing three-phase generator .............................................................11
Disassembling the three-phase generator ........................................................................11
Removing and installing drive housing ..............................................................................................11
Removing and installing voltage regulator .........................................................................................12
Replacing starter motor ..........................................................................................................12
Removing and installing starter motor .................................................................................12
Disassembling/assembling starter motor ...........................................................................13
Replacing carbon brushes ................................................................................................................13
12 Engine electrics

13.1
Contents Page
13
Technical Data ............................................................................................................................... 3
Removing and installing Motronic control unit ...........................................................5
Replacing intake air filter element ......................................................................................5
See Group 00 ......................................................................................................................................5
Replacing air temperature sensor ......................................................................................5
Removing and installing intake air silencer ...................................................................6
Removing and installing fuel injection rail .....................................................................7
Removing and installing injectors ............................................................................................7
Removing and installing pressure regulator .................................................................8
Removing and installing throttle valve rail .....................................................................8
Removing and installing throttle valve actuator .......................................................10
Replacing and adjusting throttle valve potentiometer ..........................................10
Removing and installing intake stubs .............................................................................11
Replacing fuel hoses ................................................................................................................11
Removing and installing throttle cables ........................................................................12
Preparatory work for all Bowden cables .............................................................................12
Removing and installing throttle-opener and throttle-closer cables ......................12
Removing and installing Bowden cable of cruise-control system ..........................14
Checking fuel pressure ...........................................................................................................15
Removing and installing control unit of cruise-control system ........................15
See Group 65 ....................................................................................................................................15
Checking throttle cable play, adjusting if necessary .............................................15
See Group 00 ....................................................................................................................................15
13 Fuel preparation and control

16.1
Contents Page
16
Technical Data ............................................................................................................................... 3
Removing and installing fuel tank .......................................................................................5
Renewing fuel filter .....................................................................................................................6
Removing the fuel pump unit .....................................................................................................6
Removing/installing fuel filter .....................................................................................................7
Removing/installing fuel pump ..................................................................................................7
Installing the fuel-pump unit .......................................................................................................7
Removing/installing immersion-tube sensor ................................................................8
Calibrating the immersion-tube sensor .................................................................................8
Removing/installing roll-over valve ....................................................................................8
16 Fuel tank and lines

17.1
Contents Page
17
Technical Data ............................................................................................................................... 3
Coolant circuit ................................................................................................................................5
Removing and installing coolant hoses ...........................................................................7
Connecting hose between left and right radiators ...........................................................7
Hoses between radiators and coolant stub pipes ...........................................................7
Hose between coolant stub pipes ..........................................................................................7
Coolant hose to water pump .....................................................................................................7
Removing breather hose .............................................................................................................7
Vapour outlet hose .........................................................................................................................7
Changing coolant .........................................................................................................................8
See Group 00 ......................................................................................................................................8
Checking cooling system for leaks ....................................................................................8
Removing and installing radiator with fan ......................................................................8
Removing and installing left radiator ......................................................................................8
Removing and installing right radiator .................................................................................10
Removing and installing coolant stub pipe on engine ..........................................11
Removing and installing thermostat ................................................................................11
Troubleshooting ..........................................................................................................................12
17 Radiator

17.5
Coolant circuit
KL179000

65.8
Removing and installing control
unit of cruise-control system
– Remove left side section of fairing.
a....................................................See Group 46
– Remove upper section of fairing.
•Carefully pull Bowden cable at sleeve (1) and re-
move insert (2).
•Disconnect bayonet-type plug (arrow) of control
unit.
•Pull Bowden cable away from control unit until
approx. 1 cm (0.4 in) of cable is visible and se-
cure Bowden cable in this position with
clamp (arrow).
•Disengage nipple (3), move Bowden cable with
clamp clear.
•Disconnect plug (arrow).
•Remove screws (4) securing retaining plate to
fairing bracket.
•Remove retaining plate with control unit for
cruise control system.
•Remove screws (5) and remove control unit.
•Installation is the reverse of the removal proce-
dure.
X Tightening torques:
Retaining plate to fairing bracket.................... 8 Nm
KL130011
1
2
KL650120
3
KL650010
4
KL650020
5