BMW K 1200 LT 1999 Repair Manual
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BMW K 1200 LT 1999 Repair Manual

BMW K 1200 LT 1999 Repair Manual

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Table of Contents

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Repair Manual
K 1200 LT
BMW AG Motorcycle Division
After Sales

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Summary of Contents for BMW K 1200 LT 1999

  • Page 1 Repair Manual K 1200 LT BMW AG Motorcycle Division After Sales...
  • Page 2 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...
  • Page 3 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.

  • Page 4: Key To Symbols

    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;...

  • Page 5: Table Of Contents

    Contents Group / Chapter 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...
  • Page 6 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...

  • Page 7: Clutch

    Licence plate No. Order No. Mechanic’s signature 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...

  • Page 8: Seat

    BMW AG Motorcycle Division Pre-delivery check K 1200 LT Customer Licence plate No. Pre-delivery check Order No. Mechanic’s signature Check the shipping crate for damage Unpacking the motorcycle – unpack – inspect for damage – check that delivery is complete...

  • Page 9: Maintenance And General Instructions

    00 Maintenance and general instructions Tightening torques and Table of operating fluids Pre-delivery check Maintenance Contents Page Tightening torques ........................7 Table of operating fluids ......................19 00.1...
  • Page 10 Pre-delivery check 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...
  • Page 11 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...
  • Page 12 Maintenance 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...
  • Page 13 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-...
  • Page 14 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...
  • Page 15 Tightening torques Model K 1200 LT Connection 11 Engine Cylinder head Cylinder head bolts Joint torque Oiled before installation Wrench angle 90° Cylinder head cover Heat shield for cylinder-head cover Coolant stub pipe Intake stub pipe Split conrods Split-conrod bearing Wrench angle 80°...
  • Page 16 Model K 1200 LT Connection 11 Engine Camshafts Bearing cap Chain sprockets Intermediate flange Thrust plate, driver to intermediate flange 9 (clean thread + Loctite 243) Driver to auxiliary shaft Intermediate flange to engine block Timing case Chain tensioner to cover of timing case Screw plug for chain tensioner Timing case cover Oil/water pump...

  • Page 17: Motor

    Model K 1200 LT Connection 12 Engine electrics Spark plugs Ignition coil Ignition coil to mounting plate Mounting plate to intermediate flange Cover, shield housing Ignition signal sensor Rotor Magnetic gate Cover, ignition sensor Alternator Mount to intermediate flange Driver housing to alternator shaft Connector, lead B+ Connector, lead D+ Starter motor...

  • Page 18: Fuel Tank And Lines

    Model K 1200 LT Connection 16 Fuel tank and lines Union nut, fuel-pump unit Roll-over valve Immersion-tube sensor Fuel tank to frame M 8 Bridge to frame M 8 Bridge to frame M 6 17 Radiator Hose clips Hand-tight Fan to radiator 2 (clean thread + Loctite 2701) Water pump temperature sensor Coolant stub pipe to cylinder head...
  • Page 19 Model K 1200 LT Connection 21 Clutch Clutch-lever fitting to handlebar Grub screw in filler adapter Filler adapter to breather line 18 (clean thread + Loctite 243) Clutch housing to output shaft initial torque release second torque wrench angle 60° Cover to clutch housing Lines to clutch slave cylinder Clutch slave cylinder to gearbox...
  • Page 20 Model K 1200 LT Connection 31 Front forks Fork bridge to frame (nut micro-encapsulated) 130 (clean thread + new nut or Loctite 2701) Fork stanchion to fork bridge 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...
  • Page 21 Model K 1200 LT Connection 33 Rear wheel drive Oil drain plug Oil filler plug Speed sensor mount Threaded ring 118 (clean thread + Hylomar SQ 32) Nut, bevel drive pinion 200 (clean thread + Loctite 270) Housing cover to housing Rear wheel drive to swinging arm Reaction link to rear wheel drive Reaction link to frame...

  • Page 22: Brakes

    Model K 1200 LT Connection 34 Brakes Front brake Brake calliper to fork tube Brake disc to front wheel 21 (clean thread + Loctite 243) ABS sensor Grubscrew in filler adapter Filler adapter in brake calliper 18 (clean thread + new filler adapter or Loctite 243) Vent screw in brake calliper Brake-lever fitting to handlebar...

  • Page 23: Wheels And Tyres

    Model K 1200 LT Connection 36 Wheels and tyres Rear wheel mount Initial tightening Final tightening Quick-release axle, front wheel Initial tightening Final tightening Pinch bolt, quick-release axle 46 Frame Frame Engine cross members to main frame Engine cross members to engine Transverse tube to main frame Torsion stop, swinging-arm bushings Fitted flush with bushing (clean thread +...
  • Page 24 Model K 1200 LT Connection 46 Frame Footrests Footrest system front to frame Footrest system rear to frame Footrest rubber to footrest Shift lever to footrest plate 41 (clean thread + Loctite 243) Footbrake lever to footrest plate 41 (clean thread + Loctite 243) Stop, footbrake lever Stop screw, return spring for footbrake lever Rear section, side cases and top case...

  • Page 25: General Electrical Equipment

    Model K 1200 LT Connection 51 Equipment Non-removable screw for ignition/steering lock Lock, tank cover to bridge Locking mechanism, front seat to rear frame 52 Seat Bridge, seat to frame M 6 Bridge, seat to frame M 8 Front hinge, seat to bridge Seat, front, to carrier plate Gas-filled strut to carrier plate for seat, front Seat, rear, to rear frame...

  • Page 26: Radio And Optional Extras

    Model K 1200 LT Connection 62 Instruments Instrument cluster to fairing bracket 63 Lights Headlight to upper section of fairing Rear light cluster to case trimmer 65 Radio and optional extras Clamping nut, stub aerial Aerial holder to frame Retaining plate for cruise control system to fairing bracket Holder for temperature sensor to upper section of fairing...

  • Page 27: Table Of Operating Fluids

    83 19 9 407 855 500 ml spray housings Crack testing agent for aluminium Developer MR 70 81 22 9 407 495 500 ml spray housings Installation aid BMW chilling spray Chilling components before assembly 83 19 9 407 762 300 ml spray 00.19...
  • Page 28 00.20...
  • Page 29 Overview: K1200LT packing materials 00.21...
  • Page 30 Checking the shipping crate for damage • When the motorcycle arrives, check the crate im- mediately for damage and, if necessary, examine the contents for consequential damage. Damage discovered in Germany • Note the damage on the delivery slip. • Read the information sheet on damage in transit.

  • Page 31: Unpacking The Motorcycle

    KLPD9001 Unpacking the motorcycle Caution: Remove nails projecting from the base of the crate • Lever off the cover. or lying on the base or on the floor. • Cut the plastic sheet open and pull it off. • • Take out the separate packs of items: Dispose of the packing materials in an environ- –...

  • Page 32: Installing The Front Wheel

    Tightening torques: Crash bar to skirt bracket....... 9 Nm • Secure the crossbar belts, BMW No. 46 5 650, to the crash bars (see arrow) close to the motor- cycle. •...
  • Page 33 KL460072 Installing the footrests Installing the rear right footrest and footrest plate Installing the rear left footrest plate Note: The front fastener (1) (long pointed-top screw) on the left-hand footrest plate also serves as the an- chorage point for the battery bracket. •...
  • Page 34 KL460110 Installing the engine spoilers Installing the skirts • Install the socket (3) with nut in the left-hand en- gine spoiler. • Install rubber clip-on nuts (1) at rear of each side spoiler. • Install three clip-on nuts (6) in each side spoiler (5, 9).
  • Page 35 KL460250 Installing the top case Note: • Fit the lock cylinder. The backrest can be adjusted by shifting the top • Raise the seat. case to either the front or rear position. • Remove the rear seat. Adjust by swapping the anchorages for cover of rear •...

  • Page 36: Filling And Charging The Battery

    KLPD0070 KL610010 • • Clip the cables for the radio remote control and Release the fasteners (6) securing the battery the loudspeaker into the holders (1). tray (7) and remove the battery tray. • • Insert the top case plug connectors for the radio Lift the battery off the holder together with the remote control (3) and the loudspeaker (2).
  • Page 37 Checking brake fluid level Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint. Front brake – Place the motorcycle on its centre stand so that it is level. KL000340 Caution: The motorcycle may only be ridden with the protec-...
  • Page 38 Rear brake • Remove the reservoir cap together with the dia- phragm. – Place motorcycle on its centre stand. • Open the right-hand side case. KL000110 KL000170 • Check brake fluid level. • Top up the fluid level and, if necessary, check the brake system for leaks if the brake fluid level is below the “MAX”...

  • Page 39: Checking Tyre Pressures

    Checking clutch fluid level Checking tyre pressures • – Place the motorcycle on its centre stand so that Check/correct tyre pressures. it is level. • Turn the handlebars to full right lock. Tyre pressures: One-up......... front 2.5 bar (35.6 psi) One-up........
  • Page 40 KL460140 Installing the windscreen Checking and adjusting the motorcycle • Slightly raise the windscreen linkage. Checking the function of side stand • Install windscreen and retaining plate (3). contact switch • Tighten the four screws (1) (micro-encapsulat- ed). • Switch off the engine. •...
  • Page 41 Checking headlight beam angle, Lateral adjustment adjusting if necessary Vertical adjustment • Set suspension preload to “LOW” (turn counter- clockwise). Note: Make sure that the adjuster on the instrument-panel cover is at the “UP” position (turned counter-clock- wise as far as it will go). •...

  • Page 42: Final Inspection And Function Check

    Final inspection and function check • Fill up with fuel. • Check engine oil when engine is cold, top up if necessary. • Check clutch. • Check gear shift action. • Check reverser. • Check handbrake and foot brake • Check lights and signalling equipment: –...

  • Page 43: Key To Maintenance Intervals

    BMW Running-in Check after the first 1000 km/ — BMW Service at 10,000 km (6,000 miles)...II 600 miles. — BMW Inspection at 20,000 km (12,000 miles) .. III — BMW Annual Service........IV BMW Service After the first 10,000 km/6000 miles and each addi- tional 20,000 km/12,000 miles (at 18,000 miles ...

  • Page 44: General Instructions

    General instructions Removing the aerial Pushing the motorcycle onto a workshop platform Warning: The springs securing the side stand in position can catch as you are pushing the motorcycle onto a workshop platform. This could cause damage to the motorcycle and the workshop platform, or the mo- torcycle could topple to the side opposite the side stand.
  • Page 45 Reading the fault code memory with Checking throttle cable play, the MoDiTeC adjusting if necessary (Inspections I, II, III and IV) (Inspections I and III) • Note: Open the throttle twist grip fully at different han- Loss of power to the Motronic control unit, e.g. as a dlebar positions and then release.
  • Page 46 • Check the freedom of movement of the throttle twist grip. When released, the twistgrip must re- Warning: turn to the closed position by itself and with an Observe the hazard avoidance instructions for run- audible click. • ning internal combustion engines in enclosed spac- Check the routing of the cables if the throttle twist grip does not return to the closed position or if it is stiff.
  • Page 47 Changing the oil in the rear wheel • Reinstall the oil drain plug. • Fill with gearbox oil. drive • Reinstall the oil filler plug with a new sealing ring. • Install the exhaust bracket. Change the oil in the rear wheel drive every two years at the latest Caution: (Inspections I and III)

  • Page 48: Checking Brake Pads For Wear

    Brake pads/brake discs Rear brake pads Checking brake pads and discs for wear and replacing if necessary (Inspections II and III) Checking brake pads for wear Warning: Never permit brake pads to wear past minimum per- missible thickness. Always replace pads as a complete set. Front brake pads KL000060 Caution:...

  • Page 49: Replacing Brake Pads

    Installation is the reverse of the removal proce- dure: pay particular attention to the following. • Before installing the brake calliper, force the pis- tons fully back with resetting tool, BMW No. 34 1 500. • Check the function of the brake system. Caution: KR340270 The fluid level in the brake fluid reservoir must be at the “MAX”...
  • Page 50 Remove brake pads. KL000090 • Installation is the reverse of the removal proce- dure: pay particular attention to the following. • Before installing the brake calliper, force the pis- tons fully back with resetting tool, BMW No. 34 1 500. 00.47...

  • Page 51: Checking The Front Brake Fluid Level

    Checking the front/rear brake fluid level (Inspections I, II and III) Checking the front brake fluid level Caution: The fluid level in the brake fluid reservoir must be at the MAX mark with new brake pads. It is not possi- ble to check the maximum fill level at the inspection glass.
  • Page 52 Checking the fluid level with brake fluid reservoir open Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint. – Place the motorcycle on its centre stand so that it is level.

  • Page 53: Checking The Rear Brake Fluid Level

    Checking the rear brake fluid level Checking operation of brake system and freedom from leaks, repairing/ (Inspections I, II and III) replacing if necessary Note: (Inspection III) The volume of brake fluid (MIN/MAX) is sufficient for • pad thicknesses from new to the wear limit. Check all brake lines for damage and correct po- It is not normally necessary to add fluid to compen- sitioning.
  • Page 54 • Remove the combination switch. • Turn the handlebars to full left lock. 34 1 500 KL000180 • Using resetting tool, BMW No. 34 1 500, force the pistons fully back. KL000120 • Loosen the clamping screw (1). 00.51...
  • Page 55 • Rotate the brake fitting so that the sealing sur- face on the reservoir cap is horizontal when Caution: viewed from the side. • Tighten the clamping screw. During the bleeding process, do not permit the • Remove the reservoir cap together with the dia- brake fluid level to drop below the “MIN”...
  • Page 56 Bleeding the front right brake calliper Warning: Note: The motorcycle must not be ridden without the grub Remove the grubscrew from the filler adapter and screw screwed into the filling port. install a bleed screw instead so that the brakes can Take care when removing the bleed screw and in- be bled.
  • Page 57 KL000140 KL000900 • • Connect the bleeding device to the pressure Using resetting tool, BMW No. 34 1 500, force modulator for the rear brake (arrow). the pistons fully back. • • Open the bleed screw by half a turn.
  • Page 58 Bleeding the brake calliper Caution: Dispose of old brake fluid in an environmentally friendly manner. Brake fluid grade .........DOT 4 Tightening torque: Bleed screw ..........10 Nm Checking clutch fluid level (Inspections I, II and III) KL000300 – Place the motorcycle on its centre stand so that it is level.
  • Page 59 Changing the clutch fluid (every 40,000 km/24,000 miles) Change the clutch fluid every 2 years at the latest (Inspection III) Note: This description applies for the brake filling and bleeding unit with extraction of the brake fluid by a partial vacuum at the brake calliper. If other devices are used, comply with their manu- facturers’...
  • Page 60 • Pull the protective hose over the filling port. • Secure the bleed hose to the right skirt with a ca- Caution: ble tie. During the bleeding process, do not permit the brake fluid level to drop below the MIN mark, or else air will be drawn into the brake system.
  • Page 61 If the fuel is of poor quality, replace the fuel filter • every 20,000 km (12,000 miles). Release union nut (3) using wrench, BMW No. 16 1 710. • – Remove fuel tank. Remove fuel-pump unit (1) with gasket (2).
  • Page 62 Make sure that the arrow on the underside of the fuel tank points directly toward the arrows on the fuel-pump unit. • Tighten the union nut with wrench, BMW No. 16 1 710. • Install the fuel tank. Tightening torques: Union nut ............. 30 Nm Fuel tank to frame M 8 .........

  • Page 63: Changing Coolant

    Changing coolant (Inspection IV) Note: Change the coolant every 2 years at the latest Draining coolant – Remove left fairing sections, left battery cover and centre section of engine spoiler.............See Group 46 – Remove tank cover. KR170010 ............See Group 46 •...
  • Page 64 BMW No. 46 5 640, and cross- bar, BMW No. 46 5 650. • Carefully hoist the motorcycle with the lifting gear, BMW No. 00 1 510, until the centre stand can be freely extended and retracted. • Check whether the centre stand retracts auto- matically.
  • Page 65 KR460270 Caution: Caution: Screws (1) are secured with thread-locking com- When refitting, use new screws or clean threads and pound. Do not overheat the O-rings (3) when soften- bores and install screws with Loctite 243. ing the thread-locking compound. • Using a hot-air gun and working from the inside, Lubricant: carefully soften the thread-locking compound on...
  • Page 66 Checking the steering damper Cleaning the inductive sensor on the rear wheel (every 40,000 km/ (Inspections II and III) 24,000 miles) • Turn the handlebars to full left lock. • Waggle the front of the casing to and fro to check Clean the inductive sensor on the rear wheel the play in the piston rod and on the ball head.
  • Page 67 Checking valve clearances as far as the stop. • Caution: Insert chain tensioner pin, BMW No. 11 6 740, in Never unscrew the spark plugs before measuring timing case cover to locate the chain tensioner. valve clearances. Oil-carbon particles could be- come lodged behind the exhaust valve head and fal- sify the measurement.
  • Page 68 When turning the crankshaft, make sure that the • Take out the camshafts. timing chain does not come away from the crank- • Use a rubber extractor, BMW No. 11 3 251, to shaft sprocket. withdraw the bucket tappets from the cylinder • head.
  • Page 69 • • Turn the engine over and check the relative po- Tighten all screws until seated. • sitions of the camshaft chain sprockets and the Tighten the screws in diagonally opposite se- crankshaft (at TDC). quence, working from the inside outwards. •...
  • Page 70 • • Remove spark plugs (3) with spark plug wrench, Hand brake and foot brake, ABS • BMW No. 12 3 500. Lights and signalling equipment • • Installation is the reverse of the removal proce- Telltale and warning lights •...
  • Page 71 00.72...
  • Page 72 11 Motor Contents Page Technical Data ..........................5 Cutaway drawing of engine, K 1200 LT ................11 Preparatory work with engine installed .................13 …for removal of combined oil/water pump ...............13 …for removal of timing case cover, removal of timing chain ........13 ...for removal of cylinder head ....................14 Removing/installing engine...
  • Page 73 Contents Page Removing, disassembling and assembling cylinder head ..........22 Removing camshafts .........................22 Removing bucket-type tappets ......................22 Removing cylinder head ........................22 Removing valves ..........................22 Machining valve seat .........................23 Installing valve and valve stem seal ....................24 Removing/installing crankshaft gear and rotor flange ..........24 Removing crankshaft ........................25...
  • Page 74 Contents Page Assembling engine ........................37 Installing output shaft ........................37 Assembling the crankcase ........................37 Installing oil mesh strainer .........................38 Installing oil filter ..........................38 Installing oil sump ..........................38 Installing intermediate flange ....................39 Installing freewheel ..........................39 Installing countershaft ........................39 Installing intermediate flange ......................39 Installing output shaft sealing ring .....................39 Installing clutch housing ........................40 Installing driver ..........................40...
  • Page 75 11.4...
  • Page 76 Technical Data K 1200 LT Engine, general Engine design In-line four-stroke engine installed longitudinally, with double overhead camshafts, liquid cooling and electronic fuel injection. Location of engine number At lower rear right of engine block Cylinder bore mm (in) 70.5 (2.77) Stroke mm (in) 75 (2.95) Number of cylinders...
  • Page 77 Technical Data K 1200 LT Oil pump Oil pump Gear-type Timing chain Type Pre-stretched, endless single roller chain with 128 links Valves Included valve angle Inlet ° 20.5 Exhaust ° 19.5 Valve clearances with engine cold (max. 35 °C/95 °F) Inlet valve mm (in) 0.15…0.20 (0.059…0.079) Exhaust valve...
  • Page 78 Technical Data K 1200 LT Valve seat Valve seat angle Inlet ° 45 Exhaust ° 45 Valve seat width Inlet mm (in) 0.95…1.25 (0.037...0.049) Wear limit mm (in) 2.5 (0.10) Exhaust mm (in) 1.15…1.45 (0.045...0.057) Wear limit mm (in) 3.0 (0.12) Valve seat extl.
  • Page 79 Technical Data K 1200 LT Camshaft Inlet camshaft ° 244 Exhaust camshaft ° 232 Guide bearing dia. mm (in) 29.970…30.000 (1.1799...1.1811) Wear limit mm (in) 29.95 (1.179) Guide bearing bore mm (in) 30.020…30.041 (1.1819...1.1827) Camshaft bearing bore mm (in) 24.020…24.041 (0.9457...0.9465) Radial clearance Guide bearing mm (in) 0.020…0.071 (0.0008…0.0028)
  • Page 80 Technical Data K 1200 LT Connecting rod Big end bearing with bearing shell Radial clearance mm (in) 0.030…0.066 (0.0012...0.0026) Wear limit mm (in) 0.130 (0.0051) Piston pin bore dia. with bushing mm (in) 17.006…17.017 (0.6695...0.6699) Distance between centers mm (in) 130.9…131.1 (5.15...5.16) Permissible weight difference g (oz.) ±...
  • Page 81 Technical Data K 1200 LT Piston rings 1st groove Rectangular-section ring Height mm (in) 0.975…0.990 (0.0383...0.0389) Wear limit mm (in) 0.90 (0.035) End gap mm (in) 0.10…0.30 (0.004…0.012) Wear limit mm (in) 1.50 (0.059) Side clearance mm (in) 0.030…0.065 (0.0012...0.0026) Wear limit mm (in) 0.20 (0.007) 2nd groove Taper-face oil-control ring...
  • Page 82 Cutaway drawing of engine, K 1200 LT KL119000 11.11...
  • Page 83 11.12...
  • Page 84 Preparatory work with engine instal- …for removal of combined oil/water pump • Remove engine spoiler.............See Group 46 • Drain coolant.............See Group 17 • Drain engine oil.............See Group 00 …for removal of timing case cover, removal of timing chain Caution: Disconnect ground lead from battery and insulate.
  • Page 85 ...for removal of cylinder head Removing/installing engine Removing engine Caution: Disconnect ground lead from battery and insulate. Note: • Remove left and right fairing side sections and Engine removal is necessary for: engine spoilers. - Removal of intermediate flange ............See Group 46 - Removal of output shaft •...
  • Page 86 Remove gearbox complete with starter motor. • gate in electronics box and pull cables forward to Use hoist, BMW No. 00 1 510, to raise engine far remove. enough to take weight off mounts of cross mem- •...

  • Page 87: Installing Engine

    • Install the clutch. Connect cable for side-stand switch. • • Secure engine to hoist, BMW No. 00 1 510, and Connect ground cable to cylinder head. • disengage engine from stand, Install and tighten temperature sensor for cylin- BMW No. 00 1 490.
  • Page 88 • gasket by tapping lightly with a plastic-headed Drive out piston-ring-type oil seal (4) with drift, hammer. BMW No. 11 6 721. • • Remove the housing and loosen the gasket by Press out shaft sealing ring (5) with drift, tapping lightly with plastic-headed hammer.
  • Page 89 Install spring (3) and tighten screw plug (1), fitted Insert pump shaft (5) (lightly oiled) into the with new sealing ring (2). housing. • Place sliding sleeve, BMW No. 11 6 722, on Tightening torque: pump shaft. • Oil pressure relief valve screw plug ....35 Nm Insert shaft sealing ring (8) into the guide sleeve of pressing-in tool, BMW No.

  • Page 90: Removing Timing Chain Cover

    KR110200 Removing timing chain cover Removing ignition pulse generator • Remove cover (5). • Remove gasket (4). Removing cylinder head cover Note: Mark the position of the magnetic gate in relation to the engine block, or remove it in the top dead centre (TDC) position.
  • Page 91 KL110020 • Use pin, BMW No. 11 6 740, to prevent chain Removing/installing sealing ring in timing case tensioner (1) moving. cover • Using a drift, drive the sealing ring inwards to remove. Note: Turn the camshaft in its normal direction of rotation...

  • Page 92: Removing The Timing Chain

    KL110030 Removing the timing chain • Remove the screws securing the chain sprok- kets, holding the camshaft at the hexagon. • Remove the chain sprockets and slide rail. Caution: Centre the piston in the cylinder (cylinder 1 approx. Removing chain tensioner rail •...
  • Page 93 Turn the camshafts until the tips of the cams are 11 1 749 clear. KR110280 • Install support plate, BMW No. 11 1 749, for the KL110320 valve spring compressor at the rear of the cylin- der head (not the timing end). •...
  • Page 94 KR110290 KR110310 • Install the valve spring compressor, BMW No. 11 1 740. • Use compressor cage, BMW No. 11 1 748. D = valve diameter B = valve seat width • Caution: Machine the valve seat with turning tool, Centre the compressor cage in order to avoid da- BMW No.
  • Page 95 Place a shrink-fit tube approx. 20 mm (0.79 in) long on the valve stem and heat it up. • Drive in valve stem seal (1) with the assembly tool, BMW No. 11 5 602, until resistance is felt. Caution: Remove the shrink-fit sleeve from the valve stem. •...

  • Page 96: Removing Crankshaft

    Removing main bearings (engine installed) KL110090 • Remove the wire circlip (2) at one side. • Press out piston pin (1) with drift, BMW No. 11 6 710. • Carefully remove piston rings with piston ring pliers. KL110220 • Loosen all but one (arrow) of the main bearing Note: bolts.
  • Page 97 Checking piston dimensions 1st groove: Rectangular-section ring. 2nd groove: Taper-face oil-control ring; note pin for butt joint. 3rd groove: U-Flex ring with spring. Note: The gap in the spring must be offset by 180° in rela- tion to the Flex ring gap. Checking cylinder dimensions KL110190 •...
  • Page 98 • Assembling pistons and conrods Install only pistons of the same weight group. • Note weight tolerances when replacing conrods: use only conrods of the same weight class. Weight tolerance ......± 4 g (0.14 oz.) • Weigh the conrods to determine the weight class.

  • Page 99: Removing Intermediate Flange

    Pull the driver off by hand. • 0.03 mm (0.001 in). Use puller, BMW No. 00 8 400, if the driver is a tight fit on the shaft. Determining countershaft Average of 3 measure-...
  • Page 100 KR110090 Removing clutch housing Removing intermediate flange • Use Torx socket T 30, BMW No. 00 2 600, to release the screws. • Caution: Remove the intermediate flange and loosen the After unscrewing nut (1), do not strike the output...
  • Page 101 • Remove thrust plate (1). • Remove cup spring (2). • Remove ball bearing (3) with puller, BMW No. 00 8 570, and internal puller 21/3, BMW No. 00 8 574. • Remove retaining ring (4). Installing driver bearing •...

  • Page 102: Removing Countershaft And Layshaft With Freewheel

    KR110690 • • If the intermediate flange is installed, use puller, Pull the countershaft and layshaft out of the BMW No. 00 5 010, to remove the sealing ring. crankcase together. • Note special spring (arrow). Note: Clean the sealing ring seat.
  • Page 103 KR110160 Disassembling/assembling freewheel Disassembling freewheel • Pull washer (6) and freewheel gear (5) off the layshaft (1). • Clamp the layshaft into a vice with soft jaws (smooth side down). • Remove cover plate (4). • Pull off freewheel cage (3). •...
  • Page 104 (X) from edge is uniform. • Place support ring, BMW No. 11 6 731, in positi- Distance “X” .... 0.2…0.6 mm (0.007...0.023 in) on and remove bearing with puller, BMW No. 00 8 570, and internal puller 21/3, •...

  • Page 105: Removing Output Shaft

    Remove the O-ring for the oil mesh strainer Drive in the oil level sight glass with a drift, (arrow) from the lower part of the crankcase. BMW No. 00 5 550. • Unscrew oil filter (2) with the oil filter wrench, BMW No.
  • Page 106 • Remove circlip (4) with circlip pliers. • Disassembling output shaft Insert a puller, BMW No. 00 8 400, in the oppo- • Remove needle roller race (1) and circlip (2). site cutouts of the gearwheel and pull ball •...
  • Page 107 Engage the tensioning spring on the pin in the tensioning gear and turn it clockwise with the Use temperature measuring device, counter-holder, BMW No. 12 4 600, until the pin BMW No. 00 1 900, to check heat rise. of the tensioning gear engages the hole in the •...

  • Page 108: Assembling Engine

    KR110451 Assembling damper Note: • Insert the rubber dampers (7) into the damper housing (6). Make sure that the open end of the snap ring (arrow) is facing downward in the crankcase. • Note: Install O-rings (8, 9) for the water and oil passages. New parts must be oiled lightly.
  • Page 109 Coat the oil filter sealing ring with oil. • Install the oil filter (2), using oil-filter wrench, • BMW No. 11 4 650. Check that sealing face is clean and degreased and apply a thin coat of Omni VISC 1002, see Tightening torque: black line on sealing face with grey shading.

  • Page 110: Installing Intermediate Flange

    (arrow) projects upwards and is pre-loaded against Install the intermediate flange (with locating slee- the freewheel gear. ves). • Use Torx socket T 30, BMW No. 00 2 600, to • Insert the countershaft into the crankcase with tighten the screws. the small gearwheel facing down.

  • Page 111: Installing Crankshaft

    • Slacken and then retighten the nut (50 Nm). • Use angle-of-rotation gauge, BMW No. 11 2 500, to tighten the nut fully. Tightening torque: 1. Clutch housing nut ......... 140 Nm 2. Slacken off ............3. Retighten to ..........50 Nm 4.

  • Page 112: Measuring Crankshaft Bearing Play

    Do not turn the crankshaft any more. • Remove bearing cap. KL110160 • Secure dial gauge holder, BMW No. 00 2 500, with dial gauge in tapped bore for timing case cover. • Move the crankshaft backwards and forwards as far as it will go and take the dial gauge readings.

  • Page 113: Installing Piston With Conrod

    BMW No. 11 6 700. Use angle-of-rotation gauge, • The arrow on the piston crown must point to- BMW No. 11 2 500, to tighten the big-end wards the timing end of the engine (cylinder 1). bearing screws another 80°. •...

  • Page 114: Checking Dimensions Of Crankshaft

    • Use angle-of-rotation gauge, BMW No. 11 2 500, to tighten the big-end bea- ring screws another 80°. Tightening torque: Big end bearings .......... 20 Nm Wrench angle ............

  • Page 115: Installing Cylinder Head

    Clean the cylinder head bolts and the threads in Install angle-of-rotation gauge, the engine block. BMW No. 11 2 500, with two Torx inserts T 50, BMW No. 00 2 630. • Tighten the cylinder head bolts in the correct se- Note: quence as shown through a further 90°.

  • Page 116: Installing Camshafts

    Centre the pistons in the cylinders (cylinder 1 ap- KL110120 prox. 90° before top dead centre) to avoid damaging the valves and pistons. • Place aligning device, BMW No. 11 3 700, in • Oil the camshaft bearing journals. position and secure it to the camshaft bearing •...
  • Page 117 Install screw (9) until seated. • Tighten the bearing caps with guide rail (8). • Remove the aligning device, BMW No. 11 3 700. • Tighten the chain sprockets, holding the hexa- gon on the camshaft to prevent it from turning.

  • Page 118: Installing Timing Case Cover

    • Prevent chain tensioner from moving with pin, are installed in the correct positions (arrows). • BMW No. 11 6 740. Remove the chain tensioner pin and tighten the screw plug. • Turn the engine over and check the relative po- sitions of the camshaft sprockets and the crankshaft gear.
  • Page 119 KR110710 Installing ignition pulse generator Installing ignition pulse generator cover • Run the wire to the ignition pulse generator • Mount adjusting disc and rotor on crankshaft through a rubber grommet in the timing case co- and tighten. ver. • •...

  • Page 120: Installing Crankcase Cover

    Installing combined oil/water pump • Run the wires for the oil pressure telltale and wa- ter pump temperature sensor through the hole in the pump housing and connect them. Caution: Tighten the clutch housing before installing the oil/ water pump, so that the output shaft cannot dama- ge the pump housing.

  • Page 121: Installing Cylinder Head Cover

    Installing cylinder head cover • Install the spark plugs and ignition leads.............See Group 12 Tightening torque: Spark plug............ 20 Nm • Install the cylinder head cover gasket with the half moons first. The marks at the front and rear of the gasket and the cylinder head cover must coincide.
  • Page 122 12 Engine electrics Contents Page 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...
  • Page 123 12.2...
  • Page 124 Technical Data K 1200 LT Starter motor Type Permanent-magnet motor Gear ratio 27:1 Power rating kW 0.7 Three-phase generator Type Three-phase AC generator Gear ratio 1:1.5 Drive direct Maximum output rating W/V 840/14 Maximum current A 60 Three-phase generator speed for start of charge 1000 (24 A charge current) Max.
  • Page 125 12.4...
  • Page 126 KR110200 Removing and installing Hall-effect Removing magnetic gate transmitters Preparatory work – Remove left and right fairing side sections.............See Group 46 – Remove centre and right sections of engine spoiler. – Remove right skirt bracket. Caution: Switch off the ignition and disconnect and insulate the earth (ground) lead at the battery.
  • Page 127 KR110200 Installing the magnetic gate Installing the cover of the Hall-effect transmitter • Place adjusting disc (4) and rotor (3) on crank- shaft, and tighten. • Install magnetic gate (2) in the same position as previously marked. • Install screws (1) with washers and semi-circular washers and tighten.
  • Page 128 • Pull off spark plug caps with flat pliers. Removing and installing spark plugs • Remove spark plugs with spark plug wrench, BMW No. 12 3 500. • Installation is the reverse of the removal proce- dure. KR120160 Tightening torques: Spark plugs..........
  • Page 129 KL120040 Removing and installing coil Motorcycles without shield housing Caution: Switch off the ignition and disconnect and insulate the earth (ground) lead at the battery. – Remove left side section of fairing and engine spoiler.............See Group 46 • Remove left-hand skirt bracket. •...

  • Page 130: Timing The Ignition

    KL120050 Motorcycles with shield housing Timing the ignition Preparatory work Caution: Switch off the ignition and disconnect and insulate – Remove left and right fairing side sections. the earth (ground) lead at the battery.............See Group 46 – Remove left and right engine spoilers. –...
  • Page 131 Setting timing without Motronic 00 2 510 KR120020 • Screw dial gauge, BMW No. 00 2 510, with ex- tension, BMW No. 00 2 580, into cylinder No. 1. • Set the piston to TDC. • Set the dial gauge scale ring to “0”.
  • Page 132 Hold drive housing (4) with retaining device, Use a hex socket with universal joint to tighten the BMW No. 12 4 600, to prevent it from turning, bottom securing screw (arrow), increase tightening slacken screw (3) and remove it together with the torque by approx.
  • Page 133 Replacing starter motor Removing and installing voltage regulator Removing and installing starter motor – Remove gearbox complete with starter motor.............See Group 23 KR120130 • Remove screws (2). • Carefully open clips (1, 3, 4) and remove the housing cover. KL120080 •...
  • Page 134 KL120090 Disassembling/assembling starter motor Note: • Clamp the starter motor into a vise with soft jaws. Align plastic retainer (6), brush holder (4) and inner • Unscrew tie-rods (1). insulator (3) with the stud (arrow) inside the housing. • Install plastic retainer with insulator, carbon Caution: brush holder and screw in the housing.
  • Page 135 12.14...

  • Page 136: Fuel Preparation And Control

    13 Fuel preparation and control Contents Page 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...
  • Page 137 13.2...
  • Page 138 Technical Data K 1200 LT Fuel grade Super (premium), unleaded, 95 octane (RON) Mixture preparation Motronic MA 2.4 Fuel pressure bar (psi) 3.5 (49.80) Throttle valve stub inside dia. mm (in) 34 (1.34) Air filter Multi-layer paper element Intake stub pipe With resonance damper Throttle cable play (engine warm) [without cruise-control system]...
  • Page 139 13.4...
  • Page 140 Removing and installing Motronic Replacing air temperature sensor control unit – Remove left and right fairing side sections.............See Group 46 Warning: – Remove front seat with bridge. Comply with safety precautions when handling or ............See Group 52 • working with fuel; note that the fuel lines are pressu- Remove fastener securing fuel tank to frame.
  • Page 141 • Secure non-reusable hose clips (2, 3) with pliers, BMW No. 13 1 510. • Make sure that screw of hose clamp (4) on cylin- der No. 3 is aligned exactly in forward direction of travel.

  • Page 142: Removing And Installing Injectors

    13 3 010 13 3 010 KR130051 KR130211 • Use hose clamps, BMW No. 13 3 010, to close Note: off fuel hoses (4). It is not necessary to slacken the cable ties (1, 3). • Slacken hose clamps securing fuel hoses and disconnect fuel hoses.
  • Page 143 Remove left and right fairing side sections.............See Group 46 – Remove fuel tank.............See Group 16 • Use hose clamps, BMW No. 13 3 010, to close Warning: off fuel hoses at injection rail. Comply with safety precautions when handling or working with fuel. –...
  • Page 144 KL130040 KL130030 • • Disconnect plug (4) for switch of cruise-control Remove circlip (8). • system. Disengage throttle-closer cable (5) from its pull • Disconnect the earth (ground) cable (3) from the at the throttle valve rail and remove throttle-clos- throttle valve rail.
  • Page 145 Throttle-valve potentiometer must be con- nected. • Disconnect plug of throttle valve • actuator (arrow). Connect BMW MoDiTeC to diagnosis plug be- neath front seat. • Open the TOOLBOX menu and select Caution: THROTTLE-VALVE POTENTIOMETER or Take care not to bend the retaining bracket for the THROTTLE VALVE ACTUATOR.
  • Page 146 Removing and installing intake stubs • Remove throttle valve rail. KR130080 • Open clip (arrow) securing fuel-supply hose (1) and fuel-return hose (2). KR130090 Warning: Comply with safety precautions when handling or • Remove screws (arrows) and remove intake working with fuel. stubs complete with sealing rings.
  • Page 147 Removing and installing throttle Removing and installing throttle- cables opener and throttle-closer cables – Remove left and right handlebar trim sections. Preparatory work for all Bowden ............See Group 46 cables – Remove cover of fork bridge. – Remove left and right fairing side sections.............See Group 46 –...
  • Page 148 KL130010 • Installation is the reverse of the removal proce- dure: pay particular attention to the following. Caution: Route Bowden cables so as to avoid tight bends and make sure they are not kinked or pinched. • Route the two cables parallel; the throttle-opener cable (1) with green mark always to the outside.
  • Page 149 KL130010 Removing and installing Bowden • Installation is the reverse of the removal proce- dure: pay particular attention to the following. cable of cruise-control system • Carefully pull apart sleeve (4) and lower cable sheath (arrow) and remove insert (3). Caution: •...
  • Page 150 • Connect a test pressure gauge, BMW No. 16 1 500, to fuel-supply line (inner hose, with white mark for identification). • Start engine and allow to idle. Fuel pressure: Specification ......
  • Page 151 13.16...
  • Page 152 16 Fuel tank and lines Contents Page 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...
  • Page 153 16.2...
  • Page 154 Technical Data K 1200 LT Tank capacity Motorcycle on side stand l (Imp. gal/ Motorcycle on main stand US gal) approx. 23.5 (5.17/6.21) l (Imp. gal/ US gal) approx. 22 (4.84/5.81) including reserve of l (Imp. gal/ US gal) 4 (0.88/1.06) Type of fuel Super (premium), unleaded.
  • Page 155 16.4...

  • Page 156: Removing And Installing Fuel Tank

    ............See Group 46 KL160040 • Remove bridge for saddle, front.............See Group 52 • Use hose clamps, BMW No. 13 3 010, to close off fuel hoses behind non-opening hose clips Warning: (arrows). • Comply with safety precautions when handling or Slacken screw-type hose clips and disconnect working with fuel;...
  • Page 157 Comply with safety precautions when handling or working with fuel. • Drain fuel tank. Removing the fuel pump unit • Release union nut (3) using wrench, BMW No. 16 1 710. • Remove fuel-pump unit (1) with seal (2). 16.6...
  • Page 158 Connect fuel hoses (3, 8) to new fuel filter (5). Make sure that the arrow on the underside of the • Close clips (4, 7) with pliers, BMW No. 13 1 500. fuel tank points directly toward the arrows on the fuel-pump unit.
  • Page 159 Removing/installing immersion-tube Removing/installing roll-over valve sensor – Remove left and right fairing side sections. – Remove tank cover. – Remove left and right fairing side panels.............See Group 46 • – Remove tank cover. Disconnect the drain hose.............See Group 46 Caution: Disconnect ground lead from battery and insulate.
  • Page 160 17 Radiator Contents Page 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...
  • Page 161 17.2...
  • Page 162 Technical Data K 1200 LT Cooling system capacity Total capacity l (Imp. pints/ US quarts) 3.1 (5.46/3.28) Coolant circuit l (Imp. pints/ US quarts) 2.5 (4.40/2.64) Coolant expansion tank l (Imp. pints/ US quarts) 0.6 (1.06/0.63) Coolant Use only nitrite-free long-term antifreeze and corrosion inhibitor.
  • Page 163 17.4...
  • Page 164 Coolant circuit KL179000 17.5...
  • Page 165 17.6...
  • Page 166 KL170010 Removing and installing coolant Coolant hose to water pump hoses – Remove right section of engine spoiler. • Remove coolant hose (6) to oil/water pump. – Drain coolant.............See Group 00 Removing breather hose Connecting hose between left and Warning: right radiators Comply with safety precautions when handling or...
  • Page 167 (arrow). KL170040 • Connect pump, BMW No. 17 0 500, with adapt- er and neck, BMW No. 17 5 520, to filler neck. • Pressure-test the system; the pressure must re- main unchanged for at least 5 minutes.
  • Page 168 • Installation is the reverse of the removal proce- dure: pay particular attention to the following. KL170050 • Disconnect plug (arrow) for fan and remove air KL170040 outlet duct. Note: Route Bowden cable (arrow) for cruise control sys- tem past the air outlet duct. Before installing the air outlet duct, pass the cable for the fan through the hole in the air outlet duct and connect the plug.
  • Page 169 Removing and installing right radiator • Remove 2 screws (2) and remove air outlet duct. • Disconnect fan plug. – Remove left and right fairing side sections.............See Group 46 – Remove centre and right sections of engine spoiler. – Drain coolant.
  • Page 170 Removing and installing coolant Removing and installing thermostat stub pipe on engine – Drain coolant. – Drain coolant.............See Group 00 • ............See Group 00 Disconnect coolant hose from thermostat. – Remove left engine cross-member.............See Group 46 Kr170100 KL170030 •...

  • Page 171: Troubleshooting

    Troubleshooting Coolant overheat warning light comes on. Check coolant in expansion tank. Is coolant Add coolant. level too low? Check thermostat. Thermostat does not open. Is the left radiator warmer than the right one, Replace thermostat. and the coolant pipe to the water pump hot? Test the water pump.
  • Page 172 Excessive loss of coolant. Check coolant circuit. Reconnect or repair leak, as applicable. Coolant circuit is interrupted or leaking? Engine remains cold or warms up very slow- Check thermostat. Thermostat does not close. Are both radiators equally warm and the cool- Replace thermostat.
  • Page 173 17.14...
  • Page 174 18 Exhaust system Contents Page Technical Data ..........................3 Removing and installing exhaust heat shield ...............5 Removing and installing exhaust system ................5 Removing oxygen sensor ......................6 18.1...
  • Page 175 18.2...
  • Page 176 Technical Data K 1200 LT Exhaust system Emission control 3-way catalytic converter Silencer (muffler) Reflection/absorption silencer, non-rusting stain- less steel 18.3...
  • Page 177 18.4...
  • Page 178 Removing and installing exhaust Removing and installing exhaust heat shield system • Slacken screws securing front left footrest plate. – Remove left-hand section of engine spoiler.............See Group 46 Note: The bottom fastener of the rear footrest plate is se- cured to the battery bracket.
  • Page 179 Lightly coat thread of oxygen sensor with Never Seez compound. • Tighten the oxygen sensor at the hexagon with socket wrench insert, BMW No. 11 7 020. • Replace the O-rings at the cylinder head. • Clean threads in stirrup of exhaust bracket, coat screw threads with Loctite 243 and tighten.
  • Page 180 21 Clutch Contents Page Technical Data ..........................3 Removing and installing clutch ....................5 Preparatory work ..........................5 Removing clutch ..........................5 Removing clutch housing ......................6 Installing clutch housing ......................7 Installing clutch ..........................8 Changing the clutch fluid/bleeding the clutch system ..........9 Removing and installing clutch lines ................10 Removing and installing vent line ..................11...
  • Page 181 21.2...
  • Page 182 Technical Data K 1200 LT Clutch Type Single dry plate clutch (asbestos-free) Operation Hydraulic Clutch fluid DOT 4 brake fluid Clutch plate dia. mm (in) 180 (7.02) Wear limit: Minimum clutch plate thickness mm (in) 4.6 (0.18) (measured with tips of calipers pressed by hand against rivets of clutch plate) 21.3...
  • Page 183 21.4...

  • Page 184: Removing And Installing Clutch

    KL210011 Removing and installing clutch Removing clutch • Remove the six retaining screws (7). Preparatory work • Remove clutch housing cover (6), clutch – Remove fairing and engine spoiler. plate (5), thrust plate (4), diaphragm spring (3) – Remove the battery. and wire ring (2) from the clutch housing (1).
  • Page 185 O-ring (3) is visible. • Remove the O-ring (3). • Pull off the clutch housing (2). • Remove thrust washer (1). 11 2 821 KR210030 • Secure the holder, BMW No. 11 2 821, as illus- trated. 21.6...
  • Page 186 KL210020 Installing clutch housing • Fit the mounting fixture, BMW No. 11 2 821, on the clutch housing at the position illustrated. • Lightly oil the internal spline (2). • Install thrust washer (1) between output shaft and intermediate flange; apply a blob of grease Caution: to hold the thrust washer in place, if necessary.

  • Page 187: Installing Clutch

    • 120°: yellow on clutch housing (1), white on thrust Centre clutch plate (5) with centring mandrel, plate (4) and clutch housing cover (6). BMW No. 21 2 673, and centring bar, BMW No. 21 2 672. • • Insert wire ring (2) into clutch housing (1).
  • Page 188 Changing the clutch fluid/bleeding the clutch system Note: This description applies for the brake filling and bleeding unit with extraction of the brake fluid by a partial vacuum at the brake caliper. If other devices are used, comply with their manu- facturers’...
  • Page 189 • Pull the protective hose over the filling adapter. • Secure the breather hose to the right skirt with a Caution: cable tie. Do not permit brake fluid level to drop below the MIN mark during the bleeding process, otherwise air will be drawn into the clutch system.
  • Page 190 KL210230 Removing and installing vent line • Unscrew the banjo bolt (1) on the clutch slave cylinder. • Remove sealing rings (3) and vent line (2). • Assembly is the reverse of the disassembly pro- cedure: pay particular attention to the following. Caution: Route the vent line without kinks such that contact with the spring strut is not possible in any situation.
  • Page 191 KL210220 Removing and installing clutch Caution: pressure line Make sure that the pressure line is not kinked or – Remove left side section of fairing. pinched. – Remove fuel tank. • • Cut the cable ties on the injection rail and frame. Route the clutch pressure line as illustrated.

  • Page 192: Removing And Installing Clutch Slave Cylinder

    Removing and installing clutch • Assembly is the reverse of the disassembly pro- cedure: pay particular attention to the following. slave cylinder – Remove left fairing section, battery cover and Caution: engine spoiler. To prevent the clutch slave cylinder (6) from tilting, ............See Group 46 tighten securing screws (5, 7, 8) alternately and uni- –...
  • Page 193 Removing and installing clutch release rod – Remove left fairing section, battery cover and engine spoiler.............See Group 46 – Remove the right and left front and rear footrest plates. – Remove the exhaust system ............See Group 18 – Remove the inductive sensor on the rear wheel. –...
  • Page 194 23 Gearbox Contents Page Technical Data ..........................3 Gearbox – sectional drawing ....................5 Replacing the shaft sealing rings in the gearbox housing and gearbox cover ........................7 Replacing input shaft sealing ring at input side ..............7 Replacing output shaft sealing ring ..................7 Replacing shaft sealing ring for selector shaft of reverser ...........7...
  • Page 195 Contents Page Disassembling/assembling output shaft ................21 Disassembling output shaft .......................21 Assembling output shaft ........................22 Checking endplay .........................23 Checking/adjusting fully assembled length of gearbox shafts .........24 Checking/adjusting fully assembled length of intermediate shaft ............24 Checking/adjusting fully assembled length of output shaft ..............25 Checking/adjusting fully assembled length of input shaft ..............26 Checking/adjusting fully assembled length of selector drum .............27 Shimming selector shaft ........................28...
  • Page 196 Technical Data K 1200 LT Type of gearbox 5-speed gearbox (4 + overdrive) with integral re- verser, claw-action shift and reaction damper. Reverser actuation with lock-out mechanism for forward gears and electric safety elements, plus Hall-effect transmitter for reverser speed control by reverser control unit.
  • Page 197 23.4...
  • Page 198 Gearbox – sectional drawing KL239000 23.5...
  • Page 199 23.6...
  • Page 200 Install the sealing ring with the sealing lip facing Lightly oil the sealing lips before installing the shaft inwards, using assembly sleeve, sealing rings. BMW No. 23 4 732, and drift, BMW No. 23 4 731. Replacing input shaft sealing ring at Replacing shaft sealing ring for...
  • Page 201 • • Screw the pull rod, BMW No. 00 8 581, into the Install the new sealing ring with the sealing lip hold and use impact weight, BMW No. 00 8 582, facing inwards, using drift, BMW No. 23 4 750.
  • Page 202 KL230040 Removing and installing actuating Note: unit for reverser Install the actuating control (2) with the grip projec- tion at the top. Removing and installing actuating Make sure that all cables are correctly routed and control for reverser are not pinched or kinked. •...
  • Page 203 Disassembling/assembling double Removing gearbox switch for reverse gear Caution: Disconnect the negative cable from the battery first, followed by the positive cable. • Disconnect the battery. • Remove the left and right fairing side sections. • Remove actuating control for reverser. •...
  • Page 204 KL230010 • • Remove exhaust system. Remove actuating unit for reverser, complete • Fit lifting gear, BMW No. 00 1 510. with switch unit. • • Remove rear wheel. If the gearbox is to be fully disassembled, re- • Remove inductive sensor from rear wheel drive.
  • Page 205 • Secure front wheel in position. motor (4). • • Use workshop crane, BMW No. 46 5 640, to Compress spring and remove gear indicator raise rear of frame high enough to take weight off switch (9). gearbox mounts. •...
  • Page 206 KL230130 Disassembling gearbox Preparatory work • Remove screw (1) securing starter motor (2) and remove starter motor from gearbox housing. • Remove oil filler/level check screw (5). • Remove oil drain plug (6) and drain the oil from the gearbox into a suitable tray. •...
  • Page 207 • Use M6 adapter, BMW No. 00 8 585, and puller, KL230160 BMW No. 00 8 580, to release cover (2) of re- verser from gearbox housing and remove cover. • • Remove screw (7) and remove retaining plate (6).
  • Page 208 Turn actuating shaft so that pawl does not en- gage selector drum. • Using an M6 adapter, BMW No. 00 8 585, and puller, BMW No. 00 8 580, pull the actuating shaft out of the gearbox housing until spacer (3) is clear.
  • Page 209 Avoid damage to the housing cover and paint- ed surfaces. • Heat the bearing points in the housing to 80 °C... 100 °C (176 °F...212 °F). • Use press-off tool, BMW No. 23 4 780, to sepa- rate the housing from the housing cover. 23.16...
  • Page 210 KL230190 Removing selector drum Disassembling/assembling selector shaft • Pull the selector shafts (1) out of the selector forks. • Swing selector forks (2, 8, 9) out towards the edge of the cover. • Remove locking pin (5). • Press guide plate (4) in the opposite direction to the spring loading (arrow).

  • Page 211: Removing Gearbox Shafts

    If the grooved ball bearings are replaced, the fully Pull off the grooved ball bearings with a universal assembled length must be re-adjusted. puller, BMW No. 00 7 500. • Press the output-side grooved ball bearing on to the intermediate shaft.
  • Page 212 (3), thrust block (2) and constant- speed gear (1). • Clamp input shaft (10) other way round in vise. • Use universal puller, BMW No. 00 7 500, and 00 7 500 pressure head (arrow) to pull off grooved ball bearing (11). KR230090 •...
  • Page 213 KR230081 Assembling input shaft Checking travel of spring segment on input shaft • Lightly oil the bearing surface for constant-speed gear (1) on input shaft (10), and install the con- stant-speed gear. • Lightly oil the splines in thrust block (2) and install •...

  • Page 214: Disassembling/Assembling Output Shaft

    Turn output shaft (6) other way round and clamp when removing. into the vise with soft jaws. • Use universal puller, BMW No. 00 7 500, to pull off grooved ball bearing (1). • Remove shim washer (2), needle roller bearing (3), shift gearwheel for 2nd gear (4) and thrust washer (5).

  • Page 215: Assembling Output Shaft

    KL230220 Assembling output shaft Caution: To avoid damaging the needle roller bearing on the Note: splines when installing, spread the rollers carefully Begin by installing 5th stage spur gear (12) of re- at the end face. verser. • Before assembly, oil all friction faces lightly with gear Install 5th stage spur gear (12) with narrow collar oil.

  • Page 216: Checking Endplay

    Reverse position of output shaft (6) in vise. • Install sliding gearwheel for 5th gear (14) with the • recess for the selector fork facing the 2nd gear Secure dial gauge, BMW No. 00 2 510, to dial shift wheel (4). gauge stand. • •...

  • Page 217: Checking/Adjusting Fully Assembled Length Of Gearbox Shafts

    Remove the spacing washer. Place a spacing washer (1) of the correct thick- • Locate dial gauge, BMW No. 23 4 762, in rear ness on the intermediate shaft and press on the bore of measuring fixture, BMW No. 23 4 761, grooved ball bearing.

  • Page 218: Checking/Adjusting Fully Assembled Length Of Output Shaft

    • • Locate dial gauge, BMW No. 23 4 762, in rear Place a spacing washer (1) of the correct thick- bore of measuring fixture, BMW No. 23 4 761, ness on the output shaft and press on the and set to 0.2 mm (0.008 in) preload.

  • Page 219: Checking/Adjusting Fully Assembled Length Of Input Shaft

    • • Remove the spacing washer. Remove the adapter disc, spacing washer, • Locate dial gauge, BMW No. 23 4 762, in front grooved ball bearing and reference washer. • bore of measuring fixture, BMW No. 23 4 761, •...

  • Page 220: Checking/Adjusting Fully Assembled Length Of Selector Drum

    KR230190 Checking/adjusting fully assembled length of selector drum • Place spacing washer and both thrust washers on the selector drum. • Using slide gauge, determine fully assembled length “A”. • If necessary, adjust fully assembled length “A” with a shim (arrow). Fully assembled length: Selector drum ..

  • Page 221: Shimming Selector Shaft

    Shimming selector shaft Caution: If the housing or the complete selector shaft is re- placed, the selector shaft must be measured and shimmed. KL230380 • Measure distance “C” from the shoulder on the selector shaft to the back of the sleeve. •...

  • Page 222: Assembling Gearbox

    Align the input, output and intermediate shafts so that their gearwheels mesh. KR230230 • Insert slip-over sleeve for input shaft, BMW No. 23 4 712, into cover. • • Heat bearing points in cover to 80...100 °C Place a spacing washer of the correct thickness (176...212 °F).

  • Page 223: Installing Selector Drum

    KL230280 Installing selector drum • Place a spacing washer of the correct thickness and the input-side thrust washer on selector drum (7) and secure with a small amount of grease. • Swing locking lever (6) out towards the edge of the cover and install the selector drum.

  • Page 224: Installing Gearbox Housing

    Using the metering device, apply Loctite 574 23 4 700 surface sealant to the mating face of the cover. • Place assembly sleeve, BMW No. 23 4 732, on the output shaft. KL230101 • Place assembly sleeve, BMW No. 23 4 712, on the input shaft.

  • Page 225: Installing Reverser

    KL230290 Installing reverser Note: – Select neutral. Always use a new circlip (2). • Introduce actuating shaft into gearbox housing and slip pawl (3) with long lug toward collar and driver (4) with flat toward 5th stage spur gear onto actuating shaft. –...
  • Page 226 (3). • Install bearing pin (9). • Using adapter, BMW No. 00 8 584, and pull rod, Caution: BMW No. 00 8 581, drive in bearing pin until Endplay of actuating shaft must be perceptible be- seated. •...

  • Page 227: Performing A Functional Check

    When installing cover (2), make particularly sure that: Installing cover of reverser - reverser is not engaged - 6 BMW cheesehead screws are installed (clear- ance from generator). • Reinstall securing screws for reverser cover in their original positions (as marked).

  • Page 228: Install Actuator Unit For Reverser

    KL230340 Caution: When installing the reverse gear switch, make sure that the rear retaining plate does not slip between gearbox housing and actuating lever. Actuating lever (2) must be seated against shaft col- lar. • Install new stop nut (1) and tighten. Tightening torque: Reverse gear switch on actuating shaft..

  • Page 229: Completing Assembly Of Gearbox

    KL230350 Completing assembly of gearbox Caution: Make sure that breather (1) is correctly seated in groove in bore. • Press breather (1) home in bore. Caution: Clean metal particles off the magnet in drain plug (5). • Install oil drain plug (5). KL230370 •...

  • Page 230: Installing Gearbox

    If not removed, the main (centre) stand must be re- tracted to permit installation of the gearbox. • Secure guide pins, BMW No. 23 1 820, to inter- mediate flange. • Apply a coat of Optimoly MP 3 to the splines of the gearbox input shaft.
  • Page 231 KL230010 • Insert gearbox mounting bolt (6) and tighten. Note: • Insert clutch release rod (7) into gearbox, noting Apply Loctite 243 to threads of screw (3). correct installed position. • Connect selector lever (2) to gearshift linkage. • • Position link (4) for reverser against gearbox If necessary, install screws (1) securing bearing housing.
  • Page 232 • • Fully lower the frame. Install engine spoiler. • • Remove workshop crane, BMW No. 46 5 640. Install actuating control for reverser. • • Install skirt brackets. Install left and right fairing side sections. • Connect plugs for oxygen sensor, side-stand switch, and coolant-temperature sensor.

  • Page 233: Removing And Installing Gearshift Lever And Linkage

    KL230030 Removing and installing gearshift Removing and installing gearshift lever and linkage lever • • Slacken screws securing front footrest plate. Remove screw (10). • • Remove retainer pin (2). Remove gearshift lever with bearing bushing (9). • • Disengage gearshift linkage at ball joint (1). Installation is the reverse of the removal proce- •...

  • Page 234: Aligning Rubber Mounts

    KL230050 Aligning rubber mounts • Lightly press bearing bushing against template and uniformly tighten screws (1). Aligning left-hand rubber mount Aligning right-hand rubber mount Caution: The alignment of the left-hand rubber mounts rela- Caution: tive to the frame is preset at the factory. It is not necessary to re-align the right-hand rubber Do not slacken the paint-marked Torx screws (1) mount unless the gearbox, the frame or the left-...
  • Page 235 23.42...

  • Page 236: Front Fork

    31 Front fork Contents Page Technical Data ..........................3 Removing and installing telescopic forks and fork bridge ........5 Removing telescopic fork ......................5 Removing fork bridge ........................7 Disassembling fork bridge ......................8 Removing and installing pot-type joints ....................8 Removing angular-contact ball bearing with stud ................8 Removing stud ............................9 Installing stud ............................9 Installing angular-contact ball bearing with stud ..................9...
  • Page 237 Installing left angular-contact ball bearing for leading link .........21 Installing leading link ........................22 Measuring the leading link ....................23 31.2...

  • Page 238: Technical Data

    Maximum permissible fixed fork tube runout mm (in) 0.4 (0.016) Telescopic fork oil Telescopic fork oil – approved grades BMW telescopic fork oil, SHOWA ATF Capacity per fork leg, SHOWA l (Imp. pints/ US quarts) 0.47 (0.827/0.496) Running gear Castor in normal-load position mm (in) 108.7 (4.28)
  • Page 239 31.4...

  • Page 240: Removing And Installing Telescopic Forks And Fork Bridge

    – Remove cover of fork bridge.............See Group 46 – Attach hoist, BMW No. 00 1 510, to oil sump. Removing telescopic fork Caution: Do not operate the handbrake lever when the brake calipers have been removed.
  • Page 241 • Remove screw (1) from holder (5) securing left and adapter for socket-head screw, brake line to telescopic fork. BMW No. 31 5 600. • • Remove screw (3) securing brake distributor for Pull the telescopic fork down to remove.

  • Page 242: Removing Fork Bridge

    KL310040 • Remove fastener (4) securing fork bridge to frame with socket and adapter for socket-head screw, BMW No. 31 5 600. Note: Stud is a press-fit in angular-contact ball bearing, so remove as a complete unit. Inside trim is easily scratched, so cover with mask- KL310020 ing tape or remove, if necessary.

  • Page 243: Disassembling Fork Bridge

    Heat fork bridge to 100 °C (212 °F). Warning: To avoid burns, always wear protective leather gloves when handling heated components. • Use mandrel, BMW No. 31 5 651, to remove an- gular-contact ball bearing; tap mandrel lightly 31 5 661 with plastic-headed hammer if necessary. KL310130 Note: Always replace lower wiper (4);...

  • Page 244: Removing Stud

    Loctite 2701).......... 130 Nm Fixed tube to fork bridge ......45 Nm 31 5 651 KL310160 • Using mandrel, BMW No. 31 5 651, as a rest, press stud (1) into angular-contact ball bearing (2). Installing angular-contact ball bearing with stud Note: Use temperature measuring device, BMW No.

  • Page 245: Installing Telescopic Fork

    Capacity of each fixed fork tube..0.47 +/-0.01 l (0.827 +/-0.018 Imp. pint; 0.496 +/-0.011 US quarts) Telescopic fork oil grade ....BMW telescopic fork oil KL310020 Tightening torque: Oil drain plug..........12 Nm 31.10...
  • Page 246 • From this point on, installation is the reverse of the removal procedure: pay particular attention to the following. Caution: When installing holder for brake line, use new screws or clean threads and coat with Loctite 243. • Tighten screws securing holders for brake lines. •...

  • Page 247: Assembly Specification For Telescopic Fork

    Assembly specification for telescopic Tightening torque: Bridge to slider tube fork (clean thread + Loctite 243)......21 Nm • Check that the system moves freely by com- Caution: pressing and extending the suspension (but To ensure that the fork is installed without trapped without the suspension strut) in the straight- stresses, observe the following instructions and the ahead and left/right steering lock positions.

  • Page 248: Disassembling/Assembling Telescopic Fork Leg

    Lightly oil shaft sealing ring (5), slip it onto sliding tube until seated and then, by applying the dead KL310090 weight of the tool, press in with drift, BMW No. 31 5 610, reduction with lugs, BMW No. 31 5 613, and sleeve, Caution: BMW No. 31 5 614.

  • Page 249: Measuring Telescopic Fork

    • Place both ends of fixed tube in V-blocks. • Turn fixed tube slowly and measure it with a dial gauge, BMW No. 00 2 510. Caution: Do not straighten distorted fixed tubes: always re- place them. Permissible runout: ....0.4 mm (0.016 in) Checking runout of slider tube •...

  • Page 250: Removing And Installing Slider Tube Bridge

    Support the slider tubes.............See Group 46 – Attach hoist, BMW No. 00 1 510, to oil sump. Caution: Do not operate the handbrake lever when the brake 31 5 600 calipers have been removed.

  • Page 251: Removing And Installing Ball Joint

    Coat the ball joint fastener with Optimoly TA and more than a slight turn back and forth. secure it with 46 mm (1.8 in) socket wrench in- sert, BMW No. 31 5 630, to sliding tube fork • Check/adjust ABS sensor gap.

  • Page 252: Removing And Installing Front Suspension Strut

    120°C (248°F) if necessary. • Heat fastener securing leading link to slider tube fork bridge and use socket, BMW No. 31 5 601, and adapter for socket-head screw, KL310080 BMW No. 31 5 603, to remove.

  • Page 253: Installing Suspension Strut

    Coat thread with Loctite 2701 and tighten fas- tener securing leading link to slider tube fork bridge with socket and adapter for socket-head screw, BMW No. 36 5 500. • Coat thread with Loctite 243 and tighten fasten- er securing steering damper to leading link.

  • Page 254: Removing And Installing Steering Damper

    KL310230 Removing and installing steering Caution: Fastener (1) securing steering damper to slider tube damper fork bridge (Torx) is secured with thread-locking – Remove front and rear sections of the front mud- compound. guard. • ............See Group 46 Remove fastener securing steering damper to –...

  • Page 255: Removing And Installing Leading Link

    Remove engine spoiler.............See Group 46 – Remove fuel tank.............See Group 16 • Attach hoist, BMW No. 00 1 510, to oil sump. • Remove the intake air pipe. • Remove right skirt bracket. • Detach the right radiator from its holder and KL310100 press it forward.

  • Page 256: Removing Left Angular-Contact Ball Bearing For Leading Link

    BMW No. 31 5 691, M 12 nut with mount, • Remove retaining ring (arrow) for angular-con- BMW No. 31 5 692, spacer, BMW No. 31 5 695, tact ball bearing. support, BMW No. 31 5 696, puller sleeve, BMW No. 31 5 697, and M 12 nut.

  • Page 257: Installing Leading Link

    Install angular-contact ball bearing and clamping sleeve in frame, using M 12 threaded rod, BMW No. 31 5 691, M 12 nut with mount, BMW No. 31 5 692, and puller sleeve, BMW No. 31 5 697; by screwing the M 12 threaded rod into the leading link from the left.

  • Page 258: Measuring The Leading Link

    BMW No. 31 5 682, in leading link. • Stylus of gauge, BMW No. 31 5 682, must be lo- – Remove right side section of fairing. cated in punch mark (arrow) in leading link on ............See Group 46...
  • Page 259 31.24...
  • Page 260 32 Steering Contents Page Technical Data ..........................3 Removing and installing left grip tube ................5 Removing and installing right grip tube ................6 Removing and installing clutch lever fitting ..............7 Removing and installing brake lever fitting ..............8 Removing and installing handlebar ..................9 Installation instructions for adjusting handlebar ..............10...
  • Page 261 32.2...

  • Page 262: Technical Data

    Technical Data K 1200 LT Type One-part jacketed tubular handlebar; without weights Handlebar diameter, inner tube mm (in) 22 (0.87) Handlebar diameter, outer tube mm (in) 28 (1.10) Steering lock angle ° 32 Handlebar width with grip tube mm (in) 826 (32.52) 32.3...
  • Page 263 32.4...

  • Page 264: Removing And Installing Left Grip Tube

    KL320050 Removing and installing left grip tube – [With heated grip] Remove left and right fairing side sections.............See Group 46 – [With heated grip] Remove tank cover. – [With heated grip] Remove handlebar trim. – [With heated grip] Remove fork bridge cover. •...

  • Page 265: Removing And Installing Right Grip Tube

    KL320041 Removing and installing right grip tube – [With heated grip] Remove left and right fairing side sections.............See Group 46 – [With heated grip] Remove tank cover. – [With heated grip] Remove handlebar trim. – [With heated grip] Remove fork bridge cover. •...

  • Page 266: Removing And Installing Clutch Lever Fitting

    KL320050 Removing and installing clutch lever • Remove clutch switch (1). • Remove fasteners (17) for grip. fitting • [With heated grip] Pull grip complete with – Remove left and right fairing side sections. cable (12) off handlebar, feeding cable through –...

  • Page 267: Removing And Installing Brake Lever Fitting

    KL320040 Removing and installing brake lever • Remove lower cover (6). • Remove screws (1, 8) and remove multi-function fitting switch (9) from brake-lever fitting. • Remove brake light switch (2). • – Remove left and right fairing side sections. Disengage Bowden cables at cam disc (3).

  • Page 268: Removing And Installing Handlebar

    Removing and installing handlebar – Remove left and right fairing side sections.............See Group 46 – Remove tank cover. – Remove handlebar trim. – Remove cover of fork bridge. • Remove cable ties from handlebar. • Remove left grip. • Remove right grip.

  • Page 269: Installation Instructions For Adjusting Handlebar

    Note: Use w/f 5 Allen key as gauge for adjusting. • Set distance “A”. Setting: Distance “A” ........5 mm (0.20 in) • Slightly tighten clamping screws. Handlebar: adjusting height KL320110 Caution: Make sure lines and Bowden cables are routed cor- rectly;...

  • Page 270: Removing And Installing Piston In Brake-Lever Fitting

    Removing and installing piston in • Remove pivot screw (3) and remove lever. • Clean threads of adjusting screw and pivot brake-lever fitting screw and threads in tapped bores of brake- lever fitting. • Remove rubber diaphragm from brake-lever fit- Caution: ting.

  • Page 271: Adjusting Lever Play For Front Brake/Clutch

    Adjusting lever play for front brake/ • Complete assembly of handlebar fitting. clutch Tightening torques: Front brake Pivot screw – Remove lower plastic cover from brake-lever fit- (clean thread + Loctite 2701)......11 Nm ting. – Remove cover for throttle-cable relay. Removing and installing left and right handlebar levers Caution:...
  • Page 272 33 Rear wheel drive Contents Page Technical Data ..........................3 Rear wheel drive – cutaway drawing .................5 Removing, disassembling, reassembling and installing rear wheel drive ....................7 Removing rear wheel drive ......................7 Replacing taper roller bearing in rear wheel drive ............8 Removing input bevel pinion ......................8 Disassembling input bevel pinion...
  • Page 273 Installing drive shaft ........................22 Installing rear swinging arm ......................23 Removing and installing suspension strut .................25 33.2...

  • Page 274: Technical Data

    230 (7.78), or to bottom edge of filler neck Drive shaft Layout 2-section drive shaft with integral torsional vibra- tion damper in hollow swinging arm (BMW PARALEVER), universal joint at each end, with sliding section at rear wheel drive end. Swinging arm...
  • Page 275 33.4...

  • Page 276: Rear Wheel Drive - Cutaway Drawing

    Rear wheel drive – cutaway drawing KL339000 33.5...
  • Page 277 33.6...

  • Page 278: Removing, Disassembling, Reassembling And Installing Rear Wheel Drive

    Removing, disassembling, reassembling and installing rear wheel drive – Remove rear wheel.............See Group 36 – Remove the inductive signal transmitter.............See Group 61 – Remove the brake caliper.............See Group 34 – Remove the rear wheel brake caliper and, fasten to the rear frame with the inductive sensor using a cable tie.

  • Page 279: Replacing Taper Roller Bearing In Rear Wheel Drive

    Replace circlip (4) if necessary. KL330030 • Pull out needle roller bearing (1) with reaction support, BMW No. 00 8 572, and internal puller, BMW No. 00 8 573. Note: Use temperature measuring device, BMW No. 00 1 900, to check heat rise.
  • Page 280 Never use a hammer when slackening off hex Use temperature measuring device, nut (5), or else the splines may be damaged. BMW No. 00 1 900, to check heat rise. • Heat hex nut (5) on the input bevel pinion (6) to Warning: 100 °C (212 °F) and unscrew with a 36 mm...

  • Page 281: Disassembling Input Bevel Pinion

    (splines facing upwards). • To prevent the input bevel pinion (1) from being Using puller, BMW No. 00 7 500, pull off both damaged if it falls out, use a soft underlay. bearings at the same time. •...

  • Page 282: Removing Needle Roller Bearing For Input Bevel Pinion

    • Pull out the outer race of the needle roller bearing Note: using internal puller, BMW No. 00 8 573, exten- Clean the threads of the input bevel pinion prior to sion, BMW No. 00 8 575, and reaction support, assembly.

  • Page 283: Installing Input Bevel Pinion

    Install shaft sealing ring (6) with the sealing lips fac- ing the input bevel pinion. • Oil shaft sealing ring (6) lightly and drive into threaded ring (7) with drift, BMW No. 33 1 760, and handle, BMW No. 00 5 500. 33.12...
  • Page 284 33 1 700 • Tighten hex nut (5) with 36 mm (1.4 in) socket wrench insert and reducing adapter, BMW No. 33 1 720. Tightening torques: KL330060 Threaded ring (clean thread + Hylomar SQ 32) ....118 Nm •...

  • Page 285: Removing Crown Wheel

    Remove thrust washer (6). KR330180 • Clamp crown wheel (5) into vise with soft jaws. • Insert thrust block (arrow), BMW No. 33 1 307. • Using puller, BMW No. 33 1 830, pull off grooved ball bearing (4). 33.14...

  • Page 286: Installing Crown Wheel

    Heat the housing to 80 °C (176 °F). • Insert outer race (1) into bearing seat with drift, BMW No. 23 4 670, and handle, BMW No. 00 5 500. • Check that outer race is correctly fitted by tap- ping it gently.

  • Page 287: Checking/Adjusting Backlash

    • Position measuring fixture (3), BMW No. 33 2 600, with dial gauge, BMW No. 00 2 510, on crown wheel (4) and se- cure to housing by means of screw (1). • Secure measuring arm (2), BMW No. 33 2 604, centrally to crown wheel (4).

  • Page 288: Checking Tooth Contact Pattern

    The contact pattern is adjusted by means of the like this. shim washer (1) on the input bevel pinion. • Use measuring fixture, BMW No. 33 2 600, to centre crown wheel. • Degrease tooth flanks of crown wheel and pinion and coat with engineer’s blue.

  • Page 289: Shimming Housing Cover

    Lightly oil the shaft sealing ring (1). • Using drift, BMW No. 33 1 860, and handle, KR330290 BMW No. 00 5 500, drive in shaft sealing ring (1). • Using depth gauge, measure distance “a”. Caution: Do not overheat shaft sealing ring and cordring seal.

  • Page 290: Installing Rear Wheel Drive

    Coat splines of rear universal shaft (1) with Hold floating bearing stud (7) with socket Optimoly MP 3. wrench, BMW No. 33 5 642, to prevent it turning and tighten locknut (8) with socket, BMW No. 33 6 641. •...

  • Page 291: Removing, Disassembling, Reassembling And Installing Rear Swinging Arm

    • plates. Remove left threaded ring (3). • ............See Group 46 Using socket wrench insert, BMW No. 33 6 643, – Remove left trim panel and battery cover. slacken bearing studs (4, 7) on left and right. • ............See Group 46 Remove screws (5, 6) for shock absorber.

  • Page 292: Removing And Installing Flexible Gaiter

    When installing, coat inner and outer sealing lips Engage pins (arrows) of press-out tool, (arrows) with Staburags NBU 30 PTM. BMW No. 33 6 644, in bores of threaded ring. • Press the left/right bearing out of the threaded ring.

  • Page 293: Removing Drive Shaft

    Removing drive shaft Installing drive shaft • Coat the output shaft splines with Optimoly MP 3. • Slide the front drive shaft on to the output shaft. • Snap the circlip into position by striking the drive shaft lightly with a plastic-faced hammer. KR330350 •...
  • Page 294 Screw in left/right bearing studs (1, 4). • Tighten screws (2, 3) securing suspension strut to swinging arm. 33 6 643 KL330090 • Using socket wrench insert, BMW No. 33 6 643, tighten bearing studs (1, 4) on left and right. 33.23...
  • Page 295 • Tighten the left threaded ring (3). • Hold left threaded ring (3) with socket wrench, BMW No. 33 5 642, to prevent it turning and tighten locking ring (2) with socket, BMW No. 33 6 641. • Insert circlips (1, 5) on left and right with the hook toward the outside.
  • Page 296 Removing and installing suspension strut • Remove left and right fairing side sections.............See Group 46 • Remove left and right rear footrest plates.............See Group 46 • Remove the right-hand battery cover.............See Group 46 • Remove fuel tank.............See Group 16 KL330120 •...
  • Page 297 33.26...
  • Page 298 34 Brakes Contents Page Technical Data ..........................3 Front brake calliper ........................5 Removing and installing front brake calliper ...............5 Removing and installing filler adapter ..................6 Removing and installing front brake pistons ...............7 Rear brake calliper ........................7 Removing and installing rear brake calliper ................7 Removing and installing rear brake pistons ................8...
  • Page 299 Contents Page Removing and installing front brake lines/hoses .............19 Removing front brake lines/hoses ..................19 Preparatory work ..........................19 Brake lines under fuel tank ........................20 Brake line/hose to telescopic fork .....................20 Brake hose to handlebar ........................21 Installing front brake lines/hoses ...................21 Removing and installing rear brake lines/hoses ............22 Removing brake lines/hoses ....................22...

  • Page 300: Technical Data

    Technical Data K 1200 LT Brake fluid DOT 4 Brake actuation Hydraulic Front wheel Front brake 4-piston fixed callipers, floating discs Brake disc dia. mm (in) 305 (12.0) Brake disc thickness mm (in) 5.0 (0.20) Minimum thickness mm (in) 4.5 (0.18) Brake pad surface area (sq in) 2460 (3.81) Minimum lining thickness...
  • Page 301 34.4...

  • Page 302: Front Brake Calliper

    KL000080 pads. • – Drain the brake system. If necessary, press the brake pads/pistons fully back with resetting tool, BMW No. 34 1 500. • Fill and bleed the brake system.............See Group 00 • Check/adjust ABS sensor gap. Sensor gap..0.45...0.55 mm (0.018...0.022 in) Tightening torques: Brake calliper to fork slider tube....

  • Page 303: Removing And Installing Filler Adapter

    Make sure no traces of thread-locking compound penetrate the brake callipers. KL340250 • Use piston resetting tool, BMW No. 34 1 500, to locate brake pistons. • Apply compressed air to the connection bore (arrow) in the brake calliper to blow the inte- rior clear of all traces of thread-locking com- pound.

  • Page 304: Removing And Installing Front Brake Pistons

    Removing and installing rear brake – Remove the brake calliper. • Use piston resetting tool, BMW No. 34 1 500, to calliper locate two opposing brake pistons. • Insert a piece of cloth between the two brake pis- tons not located by the resetting tool.

  • Page 305: Removing And Installing Rear Brake Pistons

    ............See Group 00 • Remove pressure pads from brake pistons. • Use piston resetting tool, BMW No. 34 1 500, to locate two opposing brake pistons. • Insert a piece of cloth between the two brake pis- tons not located by the resetting tool.

  • Page 306: Removing And Installing Front Brake Disc

    Removing and installing front brake Removing and installing rear brake disc disc – Remove front wheel.............See Group 36 – Remove rear wheel.............See Group 36 – Remove the brake calliper. Note: Mark the installed position of the brake disc on the rear wheel drive, so that vertical runout of the sensor ring is not altered.

  • Page 307: Removing And Installing Front Abs Sensor

    Removing and installing front ABS sensor – Remove right side section of fairing. Caution: Disconnect ground lead from battery and insulate. • Remove the left brake calliper. KR340040 • Release the fasteners (arrows) for ABS sensor (5). • Take off ABS sensor (5) with spacing plate (4). •...

  • Page 308: Adjusting Front Abs Sensor

    Secure dial gauge holder, BMW No. 00 2 500, ABS sensor (1). • with dial gauge, BMW No. 00 2 510, and meas- Check ABS sensor gap by inserting a feeler uring shoe, BMW No. 34 2 510, to fork slider gauge (2) between ABS sensor (1) and sensor tube.

  • Page 309: Removing And Installing Rear Abs Sensor

    BMW No. 00 2 510, extension, and installing. BMW No. 00 2 661, and measuring shoe, • Remove screws securing ABS sensor (1) from BMW No. 34 2 510, to tapped bores for ABS brake calliper. sensor fasteners. • •...

  • Page 310: Checking/Adjusting Abs Sensor Gap

    Installation is the reverse of the removal proce- dure: pay particular attention to the following. • Tighten new non-reusable hose clip (7) with pli- ers, BMW No. 13 1 500. • Check and, if necessary, adjust play at piston rod.

  • Page 311: Checking/Adjusting Play At Piston Rod

    First adjust the brake light switch for the foot brake. Warning: • All adjustments must be performed by an authorised Remove right footrest plate. BMW dealer. Checking play at piston rod KL340140 • Unscrew locknut (2) at piston rod (3).

  • Page 312: Removing And Installing Abs Control Unit

    Removing and installing ABS control unit Warning: All work on the ABS control unit must be carried out by an authorised BMW workshop. Caution: Disconnect the negative battery terminal first, then the positive one. – Remove the battery. KL340050 ........See Group 00, Battery –...
  • Page 313 KL340170 KL340210 • • Remove retaining plate (1) for brake line from the Remove battery carrier (3), if necessary. battery carrier. KR340390 KL340060 • Using a small screwdriver, press end cover (5) of • Slightly raise ABS control unit (2) complete with ABS relay housing (4) in (arrow) and at the same battery carrier (3) and pull the assembly toward time pull end cover (5) upwards.

  • Page 314: Removing And Installing Abs Relay

    Removing and installing ABS relay • Installation is the reverse of the removal proce- dure: pay particular attention to the following. • Install a new end cover for the ABS relay hous- ing. Caution: • Route all cables correctly and secure with cable Disconnect the negative battery terminal first, then ties.
  • Page 315 KR340390 KL340160 • • Using a small screwdriver, press end cover (2) of Pull ABS relay (6) and ABS relay base (7) out of ABS relay housing (1) in (arrow) and at the same the housing. • time pull end cover (2) upwards. Loosen fasteners (arrows).

  • Page 316: Removing And Installing Front Brake Lines/Hoses

    KL340030 Removing and installing front brake lines/hoses Removing front brake lines/hoses Preparatory work – Remove left and right fairing side sections. – Remove the left-hand battery cover. Warning: Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressu- rised.

  • Page 317: Brake Lines Under Fuel Tank

    Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint. Wrap cloths around the ends of the pressure lines to prevent residual brake fluid escap- ing. • Drain the brake system. •...

  • Page 318: Brake Hose To Handlebar

    Installing front brake lines/hoses Brake hose to handlebar – Remove left and right handlebar trim. • ............See Group 46 Installation is the reverse of the removal proce- – Remove cover of fork bridge. dure: pay particular attention to the following. •...

  • Page 319: Removing And Installing Rear Brake Lines/Hoses

    KL340040 Removing and installing rear brake Caution: lines/hoses Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid Removing brake lines/hoses destroys paint. Wrap cloths around the ends of the pressure lines to prevent residual brake fluid escap- Preparatory work ing.

  • Page 320: Brake Hose To Brake Master Cylinder

    Brake hose to brake master cylinder Brake fluid reservoir with return hose • – Remove right engine spoiler. Remove the front right footrest plate. • • Remove the front right footrest plate. Open non-reusable hose clip (4) and disconnect return hose (1). •...
  • Page 321 Remove securing screw (arrow) securing retain- ing plate/union to rear frame. KL460330 • Secure rear frame to workshop crane, BMW No. 46 5 640. • Remove fasteners securing rear frame to main frame. Caution: When raising the rear frame, make sure that no lines are damaged.

  • Page 322: Installing Brake Lines/Hoses

    See Group 00 Always secure brake hose with stop plate. • Always replace non-reusable hose clips and close with pliers, BMW No. 13 1 500. • Check play at brake master cylinder, adjust if Replacing brake fluid and bleeding necessary.
  • Page 323 34.26...
  • Page 324 36 Wheels and tyres Contents Page Technical data ..........................3 Removing and installing front wheel .................5 Removing and installing wheel bearings ................6 Removing left/right wheel bearings ..................6 Installing right/left wheel bearing .....................7 Installing left wheel bearing .........................7 Installing right wheel bearing .......................7 Removing/installing rear wheel ....................8 Removing rear wheel...
  • Page 325 36.2...
  • Page 326 Technical data K 1200 LT Rim size Front 3.50”x17” MT H 2 Rear 5.00”x17” MT H 2 Vertical runout Front mm (in) 0.5 (0.02) Rear mm (in) 0.3 (0.01) Lateral runout Front mm (in) 0.5 (0.02) Rear mm (in) 0.3 (0.01) Tyre size Front mm (in)
  • Page 327 36.4...

  • Page 328: Removing And Installing Front Wheel

    KL360011 Removing and installing front wheel • Installation is the reverse of the removal proce- dure: pay particular attention to the following. • Grease the quick-release axle (1) and bearing – Remove front section of front mudguard. cover (3) lightly with Shell Retinax EP2.............See Group 46 Note: Caution:...

  • Page 329: Removing And Installing Wheel Bearings

    Lever out shaft seal (1). KR360060 • Remove circlip (2) with circlip pliers. • Place support ring, BMW No. 36 6 640, on wheel hub. Note: Use temperature measuring device, BMW No. 00 1 900, to check heat rise. •...

  • Page 330: Installing Right/Left Wheel Bearing

    • 00 5 500 Using handle for drift, BMW No. 00 5 500, and drift, BMW No. 36 5 512, press in the wheel bea- ring until it is seated on the inner ring of the spa- cer bushing. 36 5 512 KR360070 •...

  • Page 331: Removing/Installing Rear Wheel

    Removing/installing rear wheel Installing rear wheel – The contact faces on the spacing washer, the Removing rear wheel rear wheel drive and the wheel hub must be free – Select first gear. from grease and clean. • Remove number plate carrier. KL460040 KL360020 •...

  • Page 332: Static Balancing Of Front And Rear Wheels

    Static balancing of front wheel The rear wheel can also be balanced dynamically. – Level balancer, BMW No. 36 3 600, using knur- – Level balancer, BMW No. 36 3 600, using knur- led-head screws (2) and spirit level (1).

  • Page 333: Checking Front/Rear Wheel Rim For Run-Out

    Lock the balancing shaft at the balancing stand with the pin (arrow) to prevent it from turning. • Install dial gauge, BMW No. 00 2 510, in the dial gauge holder on the balancer and adjust it to suit the task.

  • Page 334: Checking Rear Wheel Rim For Run-Out

    Lock the balancing shaft at the balancing stand with the pin (arrow) to prevent it from turning. • Install dial gauge, BMW No. 00 2 510, in the dial gauge holder on the balancer and adjust it to suit the task.
  • Page 335 36.12...
  • Page 336 46 Frame Contents Page Technical Data ..........................5 Overview of fairing sections, K 1200 LT ................7 Removing and installing fairing side section ..............8 Removing and installing mirror ....................8 Removing and installing fin ......................8 Removing and installing front turn indicator ...............8 Removing and installing bottom of tank cover ..............9 Removing and installing fairing skirt...
  • Page 337 Contents Page Removing and installing left/right handlebar trim ............19 Removing and installing fork bridge cover ..............19 Removing/installing interior trim ..................20 Removing and installing left/right wind deflectors ..........20 Removing and installing front mudguard ..............21 Removing and installing front mudguard front section ..........21 Removing and installing front mudguard rear section ..........21...
  • Page 338 Contents Page Removing and installing side case ..................32 Removing and installing side case lid ..................33 Removing and installing rear moulding ................33 Removing and installing rear carrier section ..............34 Removing rear mudguard ......................34 Removing and installing front fairing bracket ............35 Removing reflectors ........................36 Removing upper reflector ........................36 Removing lower reflector ........................36...
  • Page 339 46.4...
  • Page 340 Technical Data K 1200 LT Location of type plate/frame number Beneath seat, panel on right-hand side at rear frame Dimensions Overall length mm (in) 2508 (98.7) Maximum height ECE/US (windscreen retracted) mm (in) 1395/1475 (55.0/58.1) Maximum height (aerial) mm (in) 1915 (75.4) Maximum width across mirrors mm (in) 1080 (42.5) Height of seat at unladen weight...
  • Page 341 46.6...

  • Page 342: Overview Of Fairing Sections, K 1200 Lt

    Overview of fairing sections, K 1200 LT 46.7...

  • Page 343: Removing And Installing Fairing Side Section

    KL460010 Removing and installing fairing side Removing and installing fin section • Release 3 fasteners (2). • Remove fin (1). Removing and installing mirror Removing and installing front turn indicator • Remove fasteners (3) at front. • Disengage front turn indicator housing. •...

  • Page 344: Removing And Installing Bottom Of Tank Cover

    KL460010 Removing and installing bottom of Removing skirt tank cover • Release 3 fasteners (4). • – Open the front seat. Remove skirt (5). • – Open the flap of the radio control unit. Installation is the reverse of the removal proce- •...

  • Page 345: Removing And Installing Fairing Side Section

    KL460010 Removing and installing fairing side • Install securing screws (1). section • Release 10 fasteners (2). Note: When installing, note the position of the front corner (arrow) of the fairing side section relative to the en- gine spoiler. • [Right] Install 9 fasteners in clockwise direction.

  • Page 346: Removing And Installing Tank Cover

    KL460190 Removing and installing tank cover Removing flap of radio compartment – Remove fairing side sections. • Release 6 fasteners (1). KL460400 • Release 2 fasteners (9). KL610380 • Remove flap of radio compartment (7). • Remove stud (8). • •...

  • Page 347: Removing And Installing Engine Spoiler

    KL460110 Removing and installing engine spoiler • Remove reverser actuating control (3). • [Left] Remove plug (1) for on-board power socket (2). • Remove 3 anchorages (4) on engine-spoiler side section. Note: The centre section of the engine spoiler can be re- moved complete with one side section.

  • Page 348: Removing/Installing Components Mounted On Side Section Of Fairing

    KL460080 Removing/installing components mounted on side section of fairing Removing air outlet duct • • Release 4 fasteners (1). Installation is the reverse of the removal proce- • Remove air outlet duct (2). dure. Removing kneepad • Release 7 fasteners (4). •...

  • Page 349: Removing And Installing Battery Cover

    KL460210 Removing and installing battery cover – Remove fairing side section. Note: The bottom fastener of the left-hand rear footrest plate is also the anchorage point for the battery car- rier. When removing the battery cover, slacken but do not remove this screw. –...

  • Page 350: Removing Windscreen

    KL460140 Removing windscreen Removing windscreen cover • Slightly raise the windscreen. • From the inside (arrow), unclip windscreen cover (2) from its mount (3). Removing windscreen • Remove 4 fasteners (1) (micro-encapsulated). • Remove windscreen and retaining plates (4). • Installation is the reverse of the removal proce- dure: pay particular attention to the following.

  • Page 351: Removing And Installing Windscreen Adjuster

    KL460360 Removing and installing windscreen adjuster – Remove upper section of fairing. Caution: Do not separate the electric drive for the windscreen adjuster from its holder. • Open the cable ties (arrows). • Disconnect plug (3). • Remove plug (3) and relay (4) from fairing brack- •...

  • Page 352: Removing And Installing Instrument Cover

    KL460230 Removing and installing instrument cover • From the left (arrow), unclip the light from the in- ner cover. • Remove 1 fastener (5) behind the light. • Remove 2 long fasteners (1) from the windscreen adjuster. • Remove 2 long fasteners (3), 2 short fasteners (6) from below the cover.

  • Page 353: Removing And Installing Upper Section Of Fairing

    KL460130 Removing and installing upper section of fairing – Remove left and right fairing side sections. – Remove windscreen. – Remove instrument cover. • Remove headlight adjuster (1). • Disconnect temperature sensor (5) and parking- light bulb (6). • Disconnect plug for headlight (7). •...

  • Page 354: Removing And Installing Left/Right Handlebar Trim

    KL460220 Removing and installing left/right handlebar trim • Release fasteners (8). • Remove upper handlebar trim (3). • Release fasteners (6). • Remove lower handlebar trim (7). • Installation is the reverse of the removal proce- dure. Removing and installing fork bridge cover KL460410 –...

  • Page 355: Removing/Installing Interior Trim

    KL460240 Removing/installing interior trim • Carefully remove interior trim. • Disconnect plug for on-board computer. • Remove on-board computer, if necessary. • – Remove tank cover. Installation is the reverse of the removal proce- – Remove windscreen. dure: pay particular attention to the following. •...

  • Page 356: Removing And Installing Front Mudguard

    KL460100 Removing and installing front Removing and installing front mudguard mudguard rear section • Release the fastener (2). Removing and installing front • Remove the rear section of the front mudguard. mudguard front section • Installation is the reverse of the removal proce- dure.

  • Page 357: Removing And Installing Front Footrests

    KL460060 Removing and installing front • Installation is the reverse of the removal proce- dure: pay particular attention to the following. footrests • Check/adjust footbrake light switch.............See Group 61 • • Remove circlip (6) and pin (5). Check/adjust play at piston rod. •...

  • Page 358: Removing And Installing Front Left Footrest Plate

    KL460070 Removing and installing front left Removing and installing left/right footrest plate rear footrest plates • • Release 3 fasteners (4). Release 3 fasteners (2). • • Disengage ball joint (5) from gearshift lever. Remove rear footrest plate. • • Remove footrest plate (1) with gearshift lever.

  • Page 359: Removing And Installing Rear Footrests

    Removing and installing rear footrests KL460270 • Remove circlip (3). Note: When removing the stud, note the spring and ball in stop plate (1). • Remove stud (2) with spacer plate (1) and ball and spring. • Installation is the reverse of the removal proce- dure.

  • Page 360: Disassembling And Assembling Side Stand

    Disassembling and assembling side Removing and installing intake air stand pipe Warning: Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressu- rised. • Remove fuel tank............See Group 16. KR460260 • Disconnect the tension springs and take off the plate with the springs.

  • Page 361: Removing And Installing Skirt Bracket

    KL460030 Removing and installing skirt Removing and installing crash bar bracket – Remove right or left fairing side section and en- gine spoiler, as applicable. • Open cable tie on skirt bracket (1). KL460200 • Release fasteners (10) and remove cover for skirt (9).

  • Page 362: Removing And Installing Radiator Holder

    Removing and installing radiator Removing and installing rear- holder mounted components Removing and installing number-plate – Remove left and right fairing side sections and carrier tank cover. Caution: Note safety precautions; the fuel lines are pressu- rised. – Remove fuel tank.............See Group 16 –...

  • Page 363: Removing And Installing Top Case

    KL460250 Removing and installing top case Note: – Remove rear seat. The backrest can be adjusted by shifting the top • Disconnect plugs (7) and disengage the cables case to either the forward or back position. from their holders (9). Adjust by swapping the anchorages for cover of rear •...

  • Page 364: Disassembling Top Case

    KL460160 Disassembling top case Removing lid of top case – Remove the top case. – Remove the backrest. Removing/installing interior light – Remove left and right armrests (1). • From the left (arrow), unclip the light............See Group 65, • Disconnect plug.

  • Page 365: Removing Base Of Top Case

    Removing and installing rear carrier cover – Remove the top case. KL460370 Note: KL460122 Install plate with holes (1) as seat for rivet heads. Install retaining clip (2) for cable as illustrated, to- • gether with plate (1). Take out screws (7, 8). •...

  • Page 366: Removing And Installing Case Trimmer

    KL460120 Removing and installing case trimmer – Remove the top case. – Remove the rear carrier cover (8). – Remove number plate carrier (7). • Release fasteners (6) and remove rear light (4). • Disconnect plug (1). • Pull cable with rubber grommet (9) out of case trimmer.

  • Page 367: Removing And Installing Side Case

    Removing and installing side case – Remove the number plate carrier. – Remove the top case. – Remove the rear carrier cover. – Remove the case trimmer. • [Left] Disassemble knob for seat latch. • [Right] Remove CD player, if applicable. KL460380 •...

  • Page 368: Removing And Installing Side Case Lid

    KL460170 Removing and installing side case lid Removing and installing rear moulding • Drill out rivets. Caution: Do not overheat plastic parts and paint. Warning: • The strap winder is spring-loaded: risk of injury if re- Using a hot-air gun, carefully heat the moulding. •...

  • Page 369: Removing And Installing Rear Carrier Section

    KL460090 Removing and installing rear carrier Removing rear mudguard section – Remove left and right side cases. • – Remove left and right side cases. Take out 3 screws (1, 2, 5). • Pull the mudguard slightly toward the rear and remove.

  • Page 370: Removing And Installing Front Fairing Bracket

    KL460050 Removing and installing front fairing • Remove holder (arrow) for brake line from top of fairing bracket. bracket • Release fastener (4) at frame. • Release fastener (2) at top of frame. • – Remove upper section of fairing. Remove fairing bracket.

  • Page 371: Removing Reflectors

    Removing reflectors Removing and installing retaining plates in front of fork bridge – Remove upper section of fairing. – Remove upper section of fairing. – Remove interior trim. Caution: Note safety precautions; the fuel lines are pressu- rised. – Remove fuel tank.............See Group 16 –...

  • Page 372: Checking Running Gear

    Measure wheel rim width at front and rear and make a note of the figures. • Place track alignment gauge, BMW No. 36 3 920, against the left or right side of the motorcycle. KL460261 Note: In order to use the track alignment gauge on either •...

  • Page 373: Example

    Example   Formula: - - - - - – - - - -   Fixed value A (length of measuring stops) A = 50.0 mm (1.97 in) Half of rear wheel rim width - - - - - = 72.5 mm (2.85 in) Measured value B (average value)

  • Page 374: Removing And Installing Frame

    Removing and installing frame 46.39...

  • Page 375: Removing And Installing Rear Frame

    Remove shield for reverser control unit. • Secure rear frame to workshop crane, – Disconnect negative cable from battery and in- BMW No. 46 5 640, with straps. • sulate it. Remove fasteners securing exhaust to rear – Remove left and right fairing side sections.
  • Page 376 Rear footrest plate to frame......21 Nm • Remove rear frame with workshop crane, Handwheel to rear frame ......21 Nm BMW No. 46 5 640. Aerial holder to frame ........9 Nm • Installation is the reverse of the removal proce- dure: pay particular attention to the following.

  • Page 377: Removing And Installing Cross-Tube

    Removing and installing cross-tube Preparatory work • Remove left-hand side of engine spoiler. • Remove right and left front footrest plates (it is not necessary to remove the brake and gearshift levers). • Remove fasteners securing the exhaust system (it is not necessary to unplug the oxygen sensor). Additional preparations for removing engine, gearbox or main frame •...

  • Page 378: Removing And Installing Left/Right Engine Cross-Member

    Removing and installing left/right • Remove throttle-valve rail complete with intake air silencer. engine cross-member • Attach hoist, BMW No. 00 1 510, to oil sump. Caution: Note safety precautions; the fuel lines are pressu- rised. – Remove fuel tank.

  • Page 379: Removing Main Frame

    Remove fasteners securing wiring harness to frame. • Remove fairing bracket complete with electron- ics box and wiring harness and remove from workshop crane, BMW No. 46 5 640. • Secure workshop crane, BMW No. 46 5 640, to main frame. 46.44...

  • Page 380: Installing Main Frame

    ........... 9 Nm • Use workshop crane, BMW No. 46 5 640, to Suspension strut, rear, to frame ....43 Nm raise rear of frame high enough to take weight off Swinging arm to frame: gearbox mounts.
  • Page 381 Lifter handle to rear frame M 6 ...... 9 Nm Seat, rear, to rear frame ......... 9 Nm Skirt bracket M 8.......... 21 Nm Footrest system rear to frame....... 21 Nm Cover of fork bridge to holder......2 Nm Trim panels ............ 2 Nm 46.46...
  • Page 382 51 Equipment Contents Page Removing and installing ignition switch/steering lock ...........3 Removing and installing lock barrel ..................3 Removing the lock barrel ........................3 Removing lock barrel if ignition key has broken off ................3 Installing lock barrel ..........................3 Disassembling/assembling fuel tank lock ..............4 Removing and installing flap for tank cap ................4...
  • Page 383 51.2...

  • Page 384: Removing And Installing Ignition Switch/Steering Lock

    Unscrew the threaded pins with a stud remover. • KL510030 Use socket for ignition switch/steering lock, BMW No. 51 0 531, to tighten non-removable • screws. Press in the safety catch by inserting a suitable tool through the opening (arrow), e.g. a piece of Tightening torque: wire.

  • Page 385: Disassembling/Assembling Fuel Tank Lock

    Disassembling/assembling fuel Removing and installing fuel tank lock tank lock barrel – Remove fuel cap. Removing and installing flap for tank • Slightly straighten the 4 lugs in the underside of the grip one after the other and remove the barrel from the grip.

  • Page 386: Removing And Installing Lock Barrel Of Fuel Tank Cover

    Removing and installing lock barrel of fuel tank cover – Remove front seat with bridge.............See Group 52 KL510120 • Remove screws (arrows) and remove the lock. KL510160 • Insert key and turn to OPEN position. • Insert a length of wire or similar through bore (ar- row) and press in the locking pin.

  • Page 387: Removing And Installing Locking System For Front Seat

    KL510060 Removing and installing locking system for front seat – Remove left trim panel and battery cover.............See Group 46 – Remove rear seat.............See Group 52 Removing locking system • Unclip fuse box (5) and pull forward to remove. •...

  • Page 388: Removing And Installing Lock Barrel Of Side Case

    KL510040 Removing and installing lock barrel Removing and installing lock barrel of side case of top case – Open the side case. Note: Note positions of retaining plates (4, 5). • Remove retaining plates (4, 5). Warning: The strap roller is spring-loaded: risk of injury if met- al fastener (2) is suddenly released.
  • Page 389 51.8...
  • Page 390 52 Seat Contents Page Removing and installing seat ....................3 Removing and installing front seat with bridge ..............3 Removing and installing rear seat ...................3 Removing and installing rear seat backrest ................3 Disassembling/assembling front seat ................4 Removing and installing front seat ..................4 Removing and installing gas-filled strut ................4 52.1...
  • Page 391 52.2...
  • Page 392 KL460040 Removing and installing seat Removing and installing rear seat – Lift the seat at the front. Removing and installing front seat with • Remove 2 screws and remove seat. bridge • [Seat heating] Disconnect plug for seat heating. • Installation is the reverse of the removal proce- –...
  • Page 393 Disassembling/assembling front Removing and installing gas-filled strut seat – Remove front seat. • Remove retainer (1) and disengage gas-filled Removing and installing front seat strut. – Open hinged seat. KL460280 • Using a screwdriver, slightly raise clip (arrow) and disengage gas-filled strut from ball joint (3). •...
  • Page 394 61 General electrical equipment Contents Page Technical Data ..........................3 Wiring harness ..........................5 View from right ..........................5 View from left ............................6 Rear frame wiring harness ......................7 Top case wiring ..........................8 Tank cover with radio/cassette player ...................9 Connectors beside ABS control unit ..................9 Connectors on fairing bracket ....................10...
  • Page 395 Contents Page Removing and installing control unit for reverser ............18 Removing and installing inductive sensor for speedometer ......19 Removing and installing water temperature sensor ..........19 Replacing side stand switch ....................20 Removing and installing side stand switch ...............20 Check operation of side stand switch .................20 Replacing and adjusting foot brake light switch ............21...

  • Page 396: Technical Data

    Technical Data K 1200 LT Circuit voltage V 12 Battery A/h 19 Power sockets (standard equipment) 61.3...
  • Page 397 61.4...

  • Page 398: Wiring Harness

    Wiring harness View from right KL619010 61.5...

  • Page 399: View From Left

    View from left KL619020 61.6...

  • Page 400: Rear Frame Wiring Harness

    Rear frame wiring harness KL619030 61.7...

  • Page 401: Top Case Wiring

    Top case wiring KL610050 61.8...

  • Page 402: Tank Cover With Radio/Cassette Player

    Tank cover with radio/cassette player KL610040 Connectors beside ABS control unit KL610200 61.9...

  • Page 403: Connectors On Fairing Bracket

    KL610060 Connectors on fairing bracket 1 Relay for lowering adjustable windscreen 2 Brake-light switch, front brake 3 Switch for cruise control system 4 Switch for heated grips 5 Temperature sensor 6 Clutch switch for cruise control system 7 Clutch switch for starter motor 8 ABS sensor for front brake 9 On-board computer 10 Relay for raising adjustable windscreen...

  • Page 404: Relay Positions In Electronics Box

    KR610080 Relay positions in electronics box Connectors, electronics box 1 Starter relay 2 ABS warning relay 3 Relief relay 4 Fuel pump relay 5 Control unit for fuel warning light 6 Flasher unit 7 Motronic relay 8 Horn relay 9 Fan relay KL610240 10 Hall-effect sensor 11 Multi-function switch, right...

  • Page 405: Handlebar Wiring

    Handlebar wiring KL320020 KL320030 61.12...

  • Page 406: Replacing Fuses

    KL610020 Replacing fuses Fuse for radio/cassette player – Remove radio/cassette player. Motorcycle fuses ............See Group 65 – Lift the seat at the front. • Open the cover of the fuse box. • Replace the defective fuse. Fuses 1 Brake-light switch, fuel warning light, fan relay, instrument cluster, switch for adjustable windscreen 4 A 2 Parking lights, front and rear 4 A...

  • Page 407: Removing And Installing Electronics Box

    Removing and installing electronics Caution: Disconnect ground lead from battery and insulate. – Remove left and right fairing side sections. Warning: Comply with safety precautions when handling or working with fuel. – Remove fuel tank. KR610040 ............See Group 16 – Remove Motronic control unit.

  • Page 408: Disassembling Left Multi-Function Switch

    KL320051 Disassembling left multi-function • Press radiator out of holder. switch Preparatory work Caution: Disconnect ground lead from battery and insulate. – Remove left-hand handlebar trim.............See Group 46 – Remove left and right fairing side sections. – Remove cover of fork bridge. •...

  • Page 409: Removing Left Multi-Function Switch

    Disassembling right multi-function switch Caution: Disconnect ground lead from battery and insulate. – Remove left and right fairing side sections.............See Group 46 – Remove right-hand handlebar trim. – Remove cover of fork bridge. Removing and installing right multi-function switch KL610170 •...

  • Page 410: Removing Brake Light Switch

    KL320041 Removing brake light switch KL610150 • Open the cable ties (arrows). KL610150 • Disconnect plugs (8) in electronics box. • Disconnect plug (7) at fairing bracket. • • Pull cable through toward handlebar. Open the cable ties (arrows). • •...

  • Page 411: Removing And Installing Control Unit For Reverser

    Removing and installing control unit for reverser – Remove left side section of fairing.............See Group 46 – Remove the rear left footrest plate. – Remove the left-hand battery cover. – Remove rear seat. Caution: To avoid short-circuits: Disconnect negative battery lead (—) first, then positive (+) lead.

  • Page 412: Removing And Installing Inductive Sensor For Speedometer

    Inductive sensor to rear wheel drive ....4 Nm KR610220 • Install temperature sensor (3) with special wrench, BMW No. 00 2 800. Tightening torques: Temperature sensor to cylinder head ... 30 Nm Skirt bracket to frame........21 Nm 61.19...

  • Page 413: Replacing Side Stand Switch

    Replacing side stand switch • Installation is the reverse of the removal proce- dure: pay particular attention to the following. Removing and installing side stand switch Caution: Install screw and nut with Loctite 243. Note: When installing, note the correct positions of the ca- ble straps.

  • Page 414: Replacing And Adjusting Foot Brake Light Switch

    Replacing and adjusting foot brake Adjusting brake light switch light switch Removing and installing brake light switch – Remove right engine spoiler............See Group 46. – Remove the right footrest plate KL610160 • Slacken locknut (1). • Set stop of foot-brake lever to distance “A”. •...

  • Page 415: Removing And Installing Ignition Switch/Steering Lock Cable

    Removing and installing ignition • Installation is the reverse of the removal proce- dure: pay particular attention to the following. switch/steering lock cable • Seal the tapped bore for the grubscrew with sealing lacquer. • – Remove left and right fairing side sections. Carefully route the cable and secure in position with cable ties.

  • Page 416: Removing And Installing Switch For Gear Indicator

    Removing and installing switch for Removing and installing power gear indicator socket Socket on engine spoiler – Remove left side section of fairing.............See Group 46 – Remove the left-hand battery cover. – Remove left-hand side of engine spoiler. – Remove cross-tube.

  • Page 417: Removing And Installing Cable For Oil Pressure Switch / Cable For Water Pump Temperature Sensor

    Removing and installing cable for oil Installing cables pressure switch / cable for water • Introduce the cable into the bore in the pump pump temperature sensor housing. – Remove the cover from the Hall-effect transmit- ter.............See Group 12 –...
  • Page 418 62 Instruments Contents Page Technical Data ..........................3 Wiring colours ..........................5 Removing and installing instrument panel ..............6 Replacing telltale/warning lights ..................7 Telltale/warning lights ........................7 Disassembling instrument cluster ..................8 Removing speedometer, rev. counter, temperature gauge, and fuel gauge .....................8 Removing clock ..........................8 Removing and installing wiring harness ................9 62.1...
  • Page 419 62.2...

  • Page 420: Technical Data

    Technical Data K 1200 LT Instrument cluster (standard) Speedometer, rev. counter, fuel gauge, clock, gear indicator, water-temperature gauge Turn indicator repeaters 12 V 1.7 W DIN 72 601 Other telltale lights, instrument lighting 12 V 1.7 W DIN 72 601 62.3...
  • Page 421 62.4...

  • Page 422: Wiring Colours

    22 23 KL620060 Wiring colours 1 black 2 green/black 3 grey//blue, brown/blue 4 brown, brown/red 5 blue/green 6 yellow 7 grey/blue, brown/blue 8 grey/blue, brown/blue 9 yellow/violet 10 green/black 11 brown 12 brown/black, green/black 13 green/black, blue 14 brown/blue, white 15 green/black, brown/green 16 white/green, green/black 17 blue/black, brown/blue...

  • Page 423: Removing And Installing Instrument Panel

    KL620020 Removing and installing instrument panel – Remove left and right fairing side sections.............See Group 46 – Remove left and right handlebar trim. – Remove cover of fork bridge. – Remove upper section of fairing. – Remove instrument cover. •...

  • Page 424: Replacing Telltale/Warning Lights

    14 15 KL620060 Replacing telltale/warning lights Telltale/warning lights 1 Light for speedometer, rev. counter 2 Light for speedometer Note: 3 Fuel gauge light If necessary, pull gently on the cables to release the 4 Overheat warning light telltale/warning lights. 5 Battery charge warning light 6 High beam telltale –...

  • Page 425: Disassembling Instrument Cluster

    KL620010 Disassembling instrument cluster – Remove instrument panel. • Release fasteners (1) and remove bezel (4) with lens (6). Removing speedometer, rev. counter, temperature gauge, and fuel gauge Note: Note that fasteners are of different lengths and have different coatings. Make sure they are reinstalled in their original positions.

  • Page 426: Removing And Installing Wiring Harness

    Removing and installing wiring harness – Remove left and right fairing side sections.............See Group 46 – Remove upper section of fairing. Warning: Comply with safety precautions when handling or working with fuel. – Remove fuel tank.............See Group 16 –...
  • Page 427 62.10...
  • Page 428 63 Lights Contents Page Technical Data ..........................3 Removing and installing headlight ..................5 Renewing bulbs ..........................5 Bulb for low-beam headlight/ high-beam headlight ........................5 Low (dipped) beam headlight ......................5 High (main) beam headlight .........................6 Bulb, parking light ...........................6 Front turn signal ..........................6 Rear lights ............................6...
  • Page 429 63.2...
  • Page 430 Technical Data K 1200 LT Lights Headlight H7 tandem headlight with free-form reflector and manual beam throw adjustment Bulbs High (main) beam headlight H3 halogen bulb, 12 V 55 W, asymmetric, Low (dipped) beam headlight H7 halogen bulb, 12 V 55 W, asymmetric Parking light 12 V 5 W...
  • Page 431 63.4...
  • Page 432 KL630020 Removing and installing headlight Bulb for low-beam headlight/ high-beam headlight – Remove top section of fairing with headlight. • ............See Group 46 Press retaining clip (3) down and remove the • Release securing screws (arrows) for headlight housing cover (1). on top section of fairing.

  • Page 433: Rear Lights

    Rear lights High (main) beam headlight • Open side case on left or right, as appropriate. KL630030 KL630050 • Disconnect plug (1). • Bend back the ground clip (2) of the bulb for • high-beam headlight and remove the bulb Release the fastener (arrow) and remove the tail- holder.
  • Page 434 Checking headlight beam angle, adjusting if necessary Vertical adjustment • Set suspension preload to “LOW” (turn counter- clockwise). Note: Make sure that the adjuster on the instrument-panel cover is at the “UP” position (turned counter-clock- wise as far as it will go). KLPD0080 •...
  • Page 435 63.8...
  • Page 436 65 Radio and optional extras Contents Page Removing and installing speakers ..................3 Front speakers ..........................3 Preparatory work ..........................3 Treble speaker ............................3 Bass speaker ............................3 Loudspeaker box ..........................3 Rear speakers ..........................4 Removing and installing radio/cassette player ............4 Preparatory work ..........................4 Removing radio control unit .......................5 Removing radio/cassette player and wiring harness ............5...
  • Page 437 65.2...

  • Page 438: Removing And Installing Speakers

    KL620030 Removing and installing speakers Treble speaker • Carefully straighten retaining lugs (arrow) on speaker bezel (4) and remove treble speaker (2). Front speakers Bass speaker • Preparatory work Carefully lift bass speaker (5) clear of retaining – Remove upper section of fairing. plate (1).

  • Page 439: Rear Speakers

    KL460161 Rear speakers Removing and installing radio/ cassette player Preparatory work – Remove tank cover with the control unit for the radio.............See Group 46 KL650060 – Disengage retaining strap (6) from lower section of top case. • Remove screws (arrows) and remove armrest (1) with speakers from top case.

  • Page 440: Removing Radio Control Unit

    KL650090 • Disconnect plug (2) of radio control unit. Removing radio control unit • Remove fasteners (1) and remove radio control unit from tank cover. Removing radio/cassette player and wiring harness Note: Straighten the retaining lugs (arrow) before discon- necting round connector (4). KL650100 •...

  • Page 441: Removing And Installing Radio Remote Control Unit

    Removing and installing radio Removing and installing aerial remote control unit holder Removing and installing front radio remote control unit See Group 61, Removing and installing radio control unit Removing and installing rear radio remote control unit • Remove rear seat.............See Group 52 KL510010 Caution:...

  • Page 442: Removing And Installing On-Board Computer

    Removing and installing temperature sensor on upper section of fairing Note: The temperature sensor on the upper fairing meas- ures the outside temperature for display by the on- board computer. KL510150 • Remove fasteners (arrows) and remove aerial holder. • Installation is the reverse of the removal proce- dure: pay particular attention to the following.

  • Page 443: Removing And Installing Control Unit Of Cruise-Control System

    Removing and installing control unit of cruise-control system – Remove left side section of fairing.............See Group 46 – Remove upper section of fairing. KL650010 • Disconnect plug (arrow). • Remove screws (4) securing retaining plate to fairing bracket. • Remove retaining plate with control unit for cruise control system.

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