BMW K 1200 LT 1999 Manuals

Manuals and User Guides for BMW K 1200 LT 1999. We have 1 BMW K 1200 LT 1999 manual available for free PDF download: Repair Manual

BMW K 1200 LT 1999 Repair Manual (443 pages)

Brand: BMW | Category: Motorcycle | Size: 41.94 MB

Table of Contents

5
- Key to Symbols
  4
- Clutch
  7
- Seat
  8
- Maintenance and General Instructions
  9
- Motor
  17
- Fuel Tank and Lines
  18
- Brakes
  22
- Wheels and Tyres
  23
- General Electrical Equipment
  25
- Radio and Optional Extras
  26
  - Table of Operating Fluids
    27
  - Unpacking the Motorcycle
    31
  - Installing the Front Wheel
    32
  - Filling and Charging the Battery
    36
  - Checking Tyre Pressures
    39
  - Checking Tightness of Rear Wheel Studs
    39
  - Final Inspection and Function Check
    42
  - Final Cleaning
    42
  - Key to Maintenance Intervals
    43
  - General Instructions
    44
  - Checking Brake Pads for Wear
    48
  - Replacing Brake Pads
    49
  - Checking the Front Brake Fluid Level
    51
  - Checking the Brake Discs
    51
  - Checking the Rear Brake Fluid Level
    53
  - Changing Coolant
    63
  - Draining Coolant
    63
  - Installing Engine
    87
  - Removing Timing Chain Cover
    90
  - Removing the Timing Chain
    92
  - Removing Crankshaft
    96
  - Removing Intermediate Flange
    99
  - Removing Countershaft and Layshaft with Freewheel
    102
  - Removing Output Shaft
    105
  - Assembling Engine
    108
  - Installing Output Shaft
    108
  - Installing Intermediate Flange
    110
  - Installing Crankshaft
    111
  - Measuring Crankshaft Bearing Play
    112
  - Installing Piston with Conrod
    113
  - Installing Big End Bearing
    113
  - Measuring Big End Bearing Play
    113
  - Checking Dimensions of Crankshaft
    114
  - Installing Cylinder Head
    115
  - Installing Camshafts
    116
  - Installing Timing Chain
    116
  - Installing Timing Case Cover
    118
  - Installing Crankcase Cover
    120
  - Installing Cylinder Head Cover
    121
  - Timing the Ignition
    130
- Fuel Preparation and Control
  136
  - Removing and Installing Injectors
    142
  - Removing and Installing Fuel Tank
    156
  - Troubleshooting
    171
  - Removing and Installing Clutch
    184
  - Removing Clutch
    184
  - Installing Clutch
    187
  - Removing and Installing Clutch Slave Cylinder
    192
Table of Contents

195
- Removing Gearbox Shafts
  211
- Replacing Grooved Ball Bearing on Intermediate Shaft
  211
- Disassembling/Assembling Output Shaft
  214
  - Disassembling Output Shaft
    214
  - Assembling Output Shaft
    215
- Checking Endplay
  216
- Checking/Adjusting Fully Assembled Length of Gearbox Shafts
  217
- Assembling Gearbox
  
  222
  - Installing Gearbox Shafts
    222
    
    Installing Input, Output and Intermediate Shafts
    222
    
    Installing Selector Shaft
    222
    
    Installing Selector Drum
    223
  - Installing Gearbox Housing
    224
  - Installing Reverser
    225
    
    Performing a Functional Check
    227
    
    Installing Cover of Reverser
    227
    
    Install Actuator Unit for Reverser
    228
  - Completing Assembly of Gearbox
    229
- Installing Gearbox
  
  230
- Removing and Installing Gearshift Lever and Linkage
  
  233
- Removing and Installing Gearshift Lever
  
  233
- Aligning Rubber Mounts
  
  234
  - Aligning Left-Hand Rubber Mount
    234
  - Aligning Right-Hand Rubber Mount
    234
31 Front Fork

236
- Technical Data
  
  238
- Removing and Installing Telescopic Forks and Fork Bridge
  
  240
  - Removing Telescopic Fork
    240
  - Removing Fork Bridge
    242
  - Disassembling Fork Bridge
    243
    
    Removing and Installing Pot-Type Joints
    243
    
    Removing Angular-Contact Ball Bearing with Stud
    243
    
    Removing Stud
    244
    
    Installing Stud
    244
    
    Installing Angular-Contact Ball Bearing with Stud
    244
  - Installing Fork Bridge
    244
  - Installing Telescopic Fork
    245
  - Assembly Specification for Telescopic Fork
    247
  - Assembling Telescopic Fork Leg
    248
  - Disassembling Telescopic Fork Leg
    248
- Disassembling/Assembling Telescopic Fork Leg
  
  248
- Measuring Telescopic Fork
  
  249
- Removing and Installing Slider Tube Bridge
  
  250
  - Removing and Installing Ball Joint
    251
- Removing and Installing Front Suspension Strut
  
  252
  - Removing Front Suspension Strut
    252
  - Installing Suspension Strut
    253
  - Checking the Steering Damper
    254
    
    See Group 00
    254
  - Removing and Installing Steering Damper
    254
- Removing and Installing Leading Link
  
  255
  - Removing Leading Link
    255
  - Removing Left Angular-Contact Ball Bearing for Leading Link
    256
    
    Installing Leading Link
    257
    
    Measuring the Leading Link
    258
32 Steering

260
33 Rear Wheel Drive

272
34 Brakes

298
- Technical Data
  
  300
- Front Brake Calliper
  
  302
  - Removing and Installing Front Brake Calliper
    302
  - Removing and Installing Filler Adapter
    303
- Rear Brake Calliper
  
  304
- Removing and Installing Front Brake Disc
  
  306
- Removing and Installing Rear Brake Disc
  
  306
- Removing and Installing Front ABS Sensor
  
  307
- Removing Front ABS Sensor Ring
  
  307
- Adjusting Front ABS Sensor
  
  308
  - Checking/Adjusting ABS Sensor Gap
    308
    
    Checking ABS Sensor Gap
    308
    
    Adjusting ABS Sensor Gap
    308
  - Marking the ABS Sensor Ring
    308
- Adjusting Rear ABS Sensor
  
  309
  - Marking the ABS Sensor Ring
    309
- Removing and Installing Rear ABS Sensor
  
  309
  - Checking/Adjusting ABS Sensor Gap
    310
    
    Checking ABS Sensor Gap
    310
    
    Adjusting ABS Sensor Gap
    310
- Removing and Installing Rear Brake Master Cylinder
  
  310
- Checking/Adjusting Play at Piston Rod
  
  311
  - Checking Play at Piston Rod
    311
  - Adjusting Play at Piston Rod
    311
- Removing and Installing ABS Control Unit
  
  312
  - Removing and Installing ABS Relay
    314
- Removing and Installing Front Brake Lines/Hoses
  
  316
  - Removing Front Brake Lines/Hoses
    316
    
    Preparatory Work
    316
    
    Brake Lines under Fuel Tank
    317
    
    Brake Line/Hose to Telescopic Fork
    317
    
    Brake Hose to Handlebar
    318
  - Installing Front Brake Lines/Hoses
    318
- Removing and Installing Rear Brake Lines/Hoses
  
  319
  - Removing Brake Lines/Hoses
    319
    
    Preparatory Work
    319
    
    Brake Hose to Brake Calliper
    319
    
    Brake Hose to Brake Master Cylinder
    320
    
    Brake Fluid Reservoir with Return Hose
    320
    
    Brake Line to Brake Calliper
    320
- Checking Brake Fluid Level
  
  322
- Replacing Brake Fluid and Bleeding Brake System
  
  322
- Checking Brake Pads for Wear/Replacing Brake Pads
  
  322
  - Installing Brake Lines/Hoses
    322
36 Wheels and Tyres

324
- Removing and Installing Front Wheel
  
  328
- Removing and Installing Wheel Bearings
  
  329
  - Removing Left/Right Wheel Bearings
    329
  - Installing Right/Left Wheel Bearing
    330
    
    Installing Left Wheel Bearing
    330
    
    Installing Right Wheel Bearing
    330
  - Installing Rear Wheel
    331
  - Removing Rear Wheel
    331
- Removing/Installing Rear Wheel
  
  331
- Static Balancing of Front and Rear Wheels
  
  332
- Checking Front/Rear Wheel Rim for Run-Out
  
  333
  - Checking Rear Wheel Rim for Run-Out
    334
46 Frame

336
- Overview of Fairing Sections, K 1200 LT
  
  342
- Removing and Installing Fairing Side Section
  
  343
- Removing and Installing Tank Cover
  
  346
  - Removing Flap of Radio Compartment
    346
- Removing and Installing Engine Spoiler
  
  347
  - Removing Air Outlet Duct
    348
  - Removing Badge
    348
  - Removing Grille
    348
  - Removing Kneepad
    348
  - Removing Rubber Stop for Radio Cover
    348
- Removing/Installing Components Mounted on Side Section of Fairing
  
  348
- Removing and Installing Battery Cover
  
  349
- Removing Windscreen
  
  350
  - Removing Windscreen Cover
    350
  - Removing and Installing Windscreen Adjuster
    351
- Removing and Installing Instrument Cover
  
  352
- Removing and Installing Upper Section of Fairing
  
  353
- Removing and Installing Fork Bridge Cover
  
  354
- Removing and Installing Left/Right Handlebar Trim
  
  354
- Removing and Installing Left/Right Wind Deflectors
  
  355
- Removing/Installing Interior Trim
  
  355
- Removing and Installing Front Mudguard
  
  356
  - Removing and Installing Front Mudguard Front Section
    356
  - Removing and Installing Front Mudguard Rear Section
    356
- Removing and Installing Front Footrests
  
  357
- Removing and Installing Front Right Footrest Plate
  
  357
- Removing and Installing Left/Right Rear Footrest Plates
  
  358
  - Removing Gearshift Lever
    358
  - Disassembling Rear Footrest
    359
- Removing and Installing Front Left Footrest Plate
  
  358
- Removing and Installing Rear Footrests
  
  359
- Disassembling and Assembling Side Stand
  
  360
- Removing and Installing Main (Centre) Stand
  
  360
  - See Group 00, Lubricating Main Stand
    360
  - Removing and Installing Crash Bar
    361
- Removing and Installing Intake Air Pipe
  
  360
- Removing and Installing Skirt Bracket
  
  361
  - Removing and Installing Number-Plate Carrier
    362
- Removing and Installing Rear-Mounted Components
  
  362
- Removing and Installing Radiator Holder
  
  362
- Removing and Installing Front Fairing Bracket
  
  370
  - Removing and Installing Retaining Plates in Front of Fork Bridge
    371
  - Removing Reflectors
    371
    
    Removing Upper Reflector
    371
    
    Removing Lower Reflector
    371
- Checking Running Gear
  
  372
  - Measuring Wheel Track Offset
    372
    
    Example
    373
  - Checking the Leading Link for Deformation
    373
    
    See Group 31
    373
- Removing and Installing Frame
  
  374
51 Equipment

382
61 General Electrical Equipment

394
- Technical Data
  
  396
  - View from Right
    398
- Wiring Harness
  
  398
  - View from Left
    399
  - Rear Frame Wiring Harness
    400
  - Top Case Wiring
    401
  - Connectors Beside ABS Control Unit
    402
  - Tank Cover with Radio/Cassette Player
    402
  - Connectors on Fairing Bracket
    403
  - Connectors, Electronics Box
    404
  - Relay Positions in Electronics Box
    404
  - Handlebar Wiring
    405
  - Fuse for Radio/Cassette Player
    406
  - Fuses
    406
  - Motorcycle Fuses
    406
- Replacing Fuses
  
  406
- Removing and Installing Electronics Box
  
  407
- Disassembling Left Multi-Function Switch
  
  408
- Disassembling Right Multi-Function Switch
  
  409
- Removing and Installing Control Unit for Reverser
  
  411
- Removing and Installing Inductive Sensor for Speedometer
  
  412
- Removing and Installing Water Temperature Sensor
  
  412
  - Check Operation of Side Stand Switch
    413
  - Removing and Installing Side Stand Switch
    413
- Replacing Side Stand Switch
  
  413
  - Adjusting Brake Light Switch
    414
  - Removing and Installing Brake Light Switch
    414
- Replacing and Adjusting Foot Brake Light Switch
  
  414
- Removing and Installing Fanfare Horn
  
  415
- Removing and Installing Ignition Switch/Steering Lock Cable
  
  415
- Removing and Installing Switch for Gear Indicator
  
  416
  - Socket in Top Case
    416
  - Socket on Engine Spoiler
    416
  - Installing Cables
    417
- Removing and Installing Power Socket
  
  416
- Removing and Installing Battery
  
  417
  - See Group 00, Battery
    417
- Removing and Installing Battery Carrier
  
  417
  - See Group 34, Removing ABS Control Unit
    417
- Removing and Installing Cable for Oil Pressure Switch / Cable for Water Pump Temperature Sensor
  
  417
- Removing and Installing Front and Rear ABS Sensors
  
  417
  - See Group 34
    417
  - Technical Data
    420
  - Wiring Colours
    422
  - Removing and Installing Instrument Panel
    423
  - Replacing Telltale/Warning Lights
    424
  - Telltale/Warning Lights
    424
  - Disassembling Instrument Cluster
    425
    
    Removing Speedometer, Rev. Counter, Temperature Gauge, and Fuel Gauge
    425
    
    Removing Clock
    425
  - Removing and Installing Wiring Harness
    426
  - Rear Lights
    433
  - Removing Cables
    417
65 Radio and Optional Extras

436

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BMW K 1200 LT 1999 Manuals

BMW K 1200 LT 1999 Repair Manual (443 pages)

Table of Contents

Table of Contents

Table of Contents

Assembling Gearbox

Installing Gearbox

Removing and Installing Gearshift Lever and Linkage

Removing and Installing Gearshift Lever

Aligning Rubber Mounts

31 Front Fork

Technical Data

Removing and Installing Telescopic Forks and Fork Bridge

Disassembling/Assembling Telescopic Fork Leg

Measuring Telescopic Fork

Removing and Installing Slider Tube Bridge

Removing and Installing Front Suspension Strut

Removing and Installing Leading Link

32 Steering

33 Rear Wheel Drive

Technical Data

Rear Wheel Drive - Cutaway Drawing

Removing, Disassembling, Reassembling and Installing Rear Wheel Drive

Removing, Disassembling, Reassembling and Installing Rear Swinging Arm

34 Brakes

Technical Data

Front Brake Calliper

Rear Brake Calliper

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

Adjusting Rear ABS Sensor

Removing and Installing Rear ABS Sensor

Removing and Installing Rear Brake Master Cylinder

Checking/Adjusting Play at Piston Rod

Removing and Installing ABS Control Unit

Removing and Installing Front Brake Lines/Hoses

Removing and Installing Rear Brake Lines/Hoses

Checking Brake Fluid Level

Replacing Brake Fluid and Bleeding Brake System

Checking Brake Pads for Wear/Replacing Brake Pads

36 Wheels and Tyres

Removing and Installing Front Wheel

Removing and Installing Wheel Bearings

Removing/Installing Rear Wheel

Static Balancing of Front and Rear Wheels

Checking Front/Rear Wheel Rim for Run-Out

46 Frame

Overview of Fairing Sections, K 1200 LT

Removing and Installing Fairing Side Section

Removing and Installing Tank Cover

Removing and Installing Engine Spoiler

Removing/Installing Components Mounted on Side Section of Fairing

Removing and Installing Battery Cover

Removing Windscreen

Removing and Installing Instrument Cover

Removing and Installing Upper Section of Fairing

Removing and Installing Fork Bridge Cover

Removing and Installing Left/Right Handlebar Trim

Removing and Installing Left/Right Wind Deflectors

Removing/Installing Interior Trim

Removing and Installing Front Mudguard

Removing and Installing Front Footrests

Removing and Installing Front Right Footrest Plate

Removing and Installing Left/Right Rear Footrest Plates

Removing and Installing Front Left Footrest Plate

Removing and Installing Rear Footrests

Disassembling and Assembling Side Stand

Removing and Installing Main (Centre) Stand

Removing and Installing Intake Air Pipe

Removing and Installing Skirt Bracket

Removing and Installing Rear-Mounted Components

Removing and Installing Radiator Holder

Removing and Installing Front Fairing Bracket

Checking Running Gear

Removing and Installing Frame

51 Equipment

Removing and Installing Ignition Switch/Steering Lock