Bmw K1200Lt Service Repair Manual-21215B320083.pdf -Bookmark created by https://wimanual.com Repair Manual Introduction U sage Key to symbols Contents Activities Contents Maintenance schedule Pre-delivery check 00 Maintenance and general instructions Tightening torques Table of operating fluids Overview: K1200LT packing materials Checking the shipping crate for damage Damage discovered in Germany Damage discovered in importer markets Unpacking the motorcycle Installing the front wheel General instructions Pushing the motorcycle onto a workshop platform Inspecting motorcycle for damage Checking that delivery is complete Installing remaining items on motorcycle Installing the front mudguard Installing the mirrors Installing the footrests Installing the rear left footrest plate Installing the rear right footrest and footrest pl... Installing the engine spoilers Installing the reverser control Installing the skirts Installing the top case Additional instructions for moving the backrest Filling and charging the battery Checking brake fluid level Front brake Rear brake Checking clutch fluid level Checking tyre pressures Checking tightness of rear wheel studs Installing the aerial Installing the windscreen Installing the windscreen cover Checking and adjusting the motorcycle Checking the function of side stand contact switch... Adjusting the seat Adjusting the top case Checking headlight beam angle, adjusting if necess... Vertical adjustment Lateral adjustment Final inspection and function check Final cleaning Key to maintenance intervals General instructions Pushing the motorcycle onto a workshop platform High idle speed Removing the aerial Reading the fault code memory with the MoDiTeC (Inspections I, II, III and IV) Checking throttle cable play, adjusting if necess... (Inspections I and III) Models without cruise control Models with cruise control Throttle-opener cable, throttle-closer cable Cruise-control system cable Turning the throttle twist grip relative to the th... Cruise control system does not switch off Cruise control system cannot be set, or continuall... Changing engine oil, replacing oil filter element (Inspections I, II, III and IV) Changing gearbox oil Change the gearbox oil every two years at the late... (Inspection III) Changing the oil in the rear wheel drive Change the oil in the rear wheel drive every two y... (Inspections I and III) Brake pads Checking brake pads and discs for wear and replaci... (Inspections II and III) Checking brake pads for wear Front brake pads Rear brake pads Replacing brake pads Front brake Rear brake Checking the brake discs Checking the front (Inspections I, II and III) Checking the front brake fluid level Checking the fluid level with brake fluid reservoi... Checking the rear brake fluid level (Inspections I, II and III) Checking operation of brake system and freedom fro... (Inspection III) Changing brake fluid and bleeding brake system Change the brake fluid once a year at the latest (Inspection IV) Front brake Forcing back the brake pistons Opening the brake fluid reservoir Bleeding the front brake pressure modulator Bleeding the left brake calliper Bleeding the front right brake calliper Rear brake Bleeding the rear brake pressure modulator Forcing back the brake pistons Bleeding the brake calliper Checking clutch fluid level (Inspections I, II and III) Changing the clutch fluid (every40,000km Change the clutch fluid every 2 years at the lates... (Inspection III) Replacing fuel filter (every40,000km (Inspection III) Removing the fuel pump unit Removing and installing fuel filter Installing the fuel-pump unit Checking and topping up, if necessary, coolant le... (Inspections I and III) Changing coolant (Inspection IV) Draining coolant Filling coolant system Battery (Inspections III and IV) Check battery acid level and add distilled water i... Checking battery acid level Adding distilled water Installing the battery Replacing intake air filter element (Inspection III) Checking function of side stand contact switch (Inspections I, II and III) Greasing the side stand (Inspections II, III and IV) Checking the centre stand, greasing if necessary (Inspections II, III and IV) Checking the centre stand Greasing the centre stand Checking the steering damper (Inspections II and III) Checking tightness of rear wheel studs (Inspection I) Checking rear wheel bearing play by tilting wheel (Inspection III) Checking swinging arm bearings, adjusting if neces... (Inspections I and III) Cleaning the inductive sensor on the rear wheel (e... Clean the inductive sensor on the rear wheel every... (Inspection III) Checking valve clearances, adjusting if necessary... (Inspection III) Checking valve clearances Adjusting valve clearances Replacing the chain tensioning rail lining and cha... (every 60,000 km Replacing spark plugs (Inspection III) Final inspection with road safety and functional c... (Inspections I, II, III and IV) 11 Motor Cutaway drawing of engine, K 1200 LT Preparatory work with engine installed �for removal of combined oil �for removal of timing case cover, removal of timi... ...for removal of cylinder head Removing Removing engine Group: frame Groups: radiators, fuel tank and fuel lines Group: exhaust system Groups: rear-wheel drive, wheels and tyres Groups: frame and clutch Groups: engine electrical system and general vehic... Group: frame and gearbox Installing engine Groups: frame and gearbox Group: clutch Groups: engine electrical system and general vehic... Groups: frame, rear-wheel drive, wheels and tyres Group: exhaust system Groups: radiators, fuel tank and fuel lines Group: frame Disassembling engine Removing, disassembling Removing the oil Disassembling the oil Removing slipring seal and shaft sealing ring Removing the oil pressure relief valve Installing the oil pressure relief valve Oil-pressure switch, temperature sensor for water ... Installing the pump shaft with shaft sealing ring ... Installing water pump impeller Removing timing chain cover Removing cylinder head cover Removing ignition pulse generator Removing timing chain cover Removing Removing the timing chain Removing camshaft chain sprockets Removing chain tensioner rail Removing chain guide rail Renewing tensioning strap for chain tensioner rail... Removing, disassembling and assembling cylinder h... Removing camshafts Removing bucket-type tappets Removing cylinder head Removing valves Machining valve seat Installing valve and valve stem seal Removing Removing crankshaft Removing big end bearings Removing main bearings (engine installed) Removing main bearings (engine removed) Removing, disassembling and assembling piston with... Removing piston with conrod Disassembling piston Checking piston dimensions Assembling pistons Checking cylinder dimensions Checking that conrod bores are parallel Assembling pistons and conrods Measure backlash at the countershaft Removing intermediate flange Removing driver Removing clutch housing Removing intermediate flange Disassembling Removing the driver bearing Installing driver bearing Removing Removing countershaft and layshaft with freewheel Disassembling Disassembling freewheel Assembling freewheel Removing Removing bearing Removing shaft sealing ring Installing shaft sealing ring Installing bearing Removing output shaft Removing oil sump Removing the oil mesh strainer and oil filter Removing lower part of crankcase Removing Disassembling Disassembling output shaft Disassembling tensioning gear Assembling tensioning gear Assembling damper Assembling engine Installing output shaft Assembling the crankcase Installing oil mesh strainer Installing oil filter Installing oil sump Installing intermediate flange Installing freewheel Installing countershaft Installing intermediate flange Installing output shaft sealing ring Installing clutch housing Installing driver Installing crankshaft Measuring crankshaft bearing play Measuring radial play Measuring endplay Installing piston with conrod Installing big end bearing Measuring big end bearing play Checking dimensions of crankshaft Installing cylinder head Installing camshafts Installing timing chain Installing timing case cover Checking valve clearances Adjusting valve clearances Installing ignition pulse generator Installing ignition pulse generator cover Installing combined oil Installing crankcase cover Installing cylinder head cover 12 Engine electrics Removing and installing Hall-effect transmitters Preparatory work Removing cover from Hall-effect transmitter Removing magnetic gate Installing the magnetic gate Installing the cover of the Hall-effect transmitte... Replacing spark plugs Removing and installing spark plugs Removing and installing ignition leads Removing and installing coil Motorcycles without shield housing Motorcycles with shield housing Timing the ignition Preparatory work Setting timing with Motronic Setting timing without Motronic Replacing three-phase generator Removing and installing three-phase generator Disassembling the three-phase generator Removing and installing drive housing Removing and installing voltage regulator Replacing starter motor Removing and installing starter motor Disassembling Replacing carbon brushes 13 Fuel preparation and control Removing and installing Motronic control unit Replacing intake air filter element See Group00 Replacing air temperature sensor Removing and installing intake air silencer Removing and installing fuel injection rail Removing and installing injectors Removing and installing pressure regulator Removing and installing throttle valve rail Removing and installing throttle valve actuator Replacing and adjusting throttle valve potentiomet... Removing and installing intake stubs Replacing fuel hoses Removing and installing throttle cables Preparatory work for all Bowden cables Removing and installing throttle- opener and throt... Removing and installing Bowden cable of cruise-con... Checking fuel pressure Removing and installing control unit of cruise-con... See Group 65 Checking throttle cable play, adjusting if necess... See Group 00 16 Fuel tank and lines Removing and installing fuel tank Renewing fuel filter Removing the fuel pump unit Removing Removing Installing the fuel-pump unit Removing Calibrating the immersion-tube sensor Removing 17 Radiator Coolant circuit Removing and installing coolant hoses Connecting hose between left and right radiators Hoses between radiators and coolant stub pipes Hose between coolant stub pipes Coolant hose to water pump Removing breather hose Vapour outlet hose Changing coolant See Group00 Checking cooling system for leaks Removing and installing radiator with fan Removing and installing left radiator Removing and installing right radiator Removing and installing coolant stub pipe on engin... Removing and installing thermostat Troubleshooting 18 Exhaust system Removing and installing exhaust heat shield Removing and installing exhaust system Removing oxygen sensor 21 Clutch Removing and installing clutch Preparatory work Removing clutch Removing clutch housing Installing clutch housing Installing clutch Changing the clutch fluid Removing and installing clutch lines Removing and installing vent line Removing and installing clutch pressure line Removing and installing clutch slave cylinder Removing and installing clutch release rod 23 Gearbox Gearbox � sectional drawing Replacing the shaft sealing rings in the gearbox h... Replacing input shaft sealing ring at input side Replacing output shaft sealing ring Replacing shaft sealing ring for selector shaft o... Replacing input shaft sealing ring at output side Replacing shaft sealing ring for selector drum Replacing shaft sealing ring for selector shaft Removing and installing actuating unit for reverse... Removing and installing actuating control for reve... Removing and installing actuating unit for reverse... Disassembling Removing gearbox Disassembling gearbox Preparatory work Disassembling reverser gear train Removing gearbox housing Removing selector drum Disassembling Removing gearbox shafts Replacing grooved ball bearing on intermediate sha... Disassembling Disassembling input shaft Assembling input shaft Checking travel of spring segment on input shaft Disassembling Disassembling output shaft Assembling output shaft Checking endplay Checking Checking Checking Checking Checking Shimming selector shaft Assembling gearbox Installing gearbox shafts Installing input, output and intermediate shafts Installing selector shaft Installing selector drum Installing gearbox housing Installing reverser Performing a functional check Installing cover of reverser Install actuator unit for reverser Completing assembly of gearbox Installing gearbox Removing and installing gearshift lever and linkag... Removing and installing gearshift lever Aligning rubber mounts Aligning left-hand rubber mount Aligning right-hand rubber mount 31 Front fork Removing and installing telescopic forks and fork ... Removing telescopic fork Removing fork bridge Disassembling fork bridge Removing and installing pot-type joints Removing angular-contact ball bearing with stud Removing stud Installing stud Installing angular-contact ball bearing with stud Installing fork bridge Installing telescopic fork Assembly specification for telescopic fork Disassembling Disassembling telescopic fork leg Assembling telescopic fork leg Measuring telescopic fork Examining slider tube bridge and fork bridge Checking runout of fixed tube Checking runout of slider tube Removing and installing slider tube bridge Removing and installing ball joint Removing and installing front suspension strut Removing front suspension strut Installing suspension strut Removing and installing steering damper Checking the steering damper See Group 00 Removing and installing leading link Removing leading link Removing left angular-contact ball bearing for lea... Installing left angular-contact ball bearing for l... Installing leading link Measuring the leading link 32 Steering Removing and installing left grip tube Removing and installing right grip tube Removing and installing clutch lever fitting Removing and installing brake lever fitting Removing and installing handlebar Installation instructions for adjusting handlebar Handlebar: adjusting horizontally Handlebar: adjusting height Removing and installing piston in brake-lever fitt... Adjusting lever play for front brake Front brake Clutch Removing and installing left and right handlebar l... Removing and installing throttle cables See Group 13 33 Rear wheel drive Rear wheel drive � cutaway drawing Removing, disassembling, reassembling and install... Removing rear wheel drive Replacing taper roller bearing in rear wheel drive... Removing input bevel pinion Disassembling input bevel pinion Removing needle roller bearing for input bevel pin... Installing needle roller bearing for input bevel p... Assembling input bevel pinion Installing input bevel pinion Removing crown wheel Installing crown wheel Checking Checking tooth contact pattern Shimming housing cover Installing housing cover Installing rear drive shaft Installing rear wheel drive Removing, disassembling, reassembling and install... Removing rear swinging arm Removing and installing flexible gaiter Removing and installing threaded ring bearings Removing bearing from left Installing bearing in left Removing drive shaft Checking universal joint for wear Installing drive shaft Installing rear swinging arm Removing and installing suspension strut 34 Brakes Front brake calliper Removing and installing front brake calliper Removing and installing filler adapter Removing and installing front brake pistons Rear brake calliper Removing and installing rear brake calliper Removing and installing rear brake pistons Removing and installing front brake disc Removing and installing rear brake disc Removing and installing front ABS sensor Removing front ABS sensor ring Adjusting front ABS sensor Marking the ABS sensor ring Checking Checking ABS sensor gap Adjusting ABS sensor gap Removing and installing rear ABS sensor Adjusting rear ABS sensor Marking the ABS sensor ring Checking Checking ABS sensor gap Adjusting ABS sensor gap Removing and installing rear brake master cylinder... Checking Checking play at piston rod Adjusting play at piston rod Removing and installing ABS control unit Removing and installing ABS relay Removing and installing front brake lines Removing front brake lines Preparatory work Brake lines under fuel tank Brake line Brake hose to handlebar Installing front brake lines Removing and installing rear brake lines Removing brake lines Preparatory work Brake hose to brake calliper Brake hose to brake master cylinder Brake fluid reservoir with return hose Brake line to brake calliper Installing brake lines Checking brake pads for wear See Group 00 Checking brake fluid level See Group 00 Replacing brake fluid and bleeding brake system See Group 00 36 Wheels and tyres Removing and installing front wheel Removing and installing wheel bearings Removing left Installing right Installing left wheel bearing Installing right wheel bearing Removing Removing rear wheel Installing rear wheel Static balancing of front and rear wheels Static balancing of front wheel Static balancing of rear wheel Checking front Checking front wheel rim for run-out Checking rear wheel rim for run-out 46 Frame Overview of fairing sections, K 1200 LT Removing and installing fairing side section Removing and installing mirror Removing and installing fin Removing and installing front turn indicator Removing and installing bottom of tank cover Removing and installing fairing skirt Removing skirt Removing and installing fairing side section Removing and installing tank cover Removing flap of radio compartment Removing and installing engine spoiler Removing Removing air outlet duct Removing kneepad Removing grille Removing badge Removing rubber stop for radio cover Removing and installing battery cover Removing windscreen Removing windscreen cover Removing windscreen Removing and installing windscreen adjuster Removing and installing instrument cover Removing and installing upper section of fairing Removing and installing left Removing and installing fork bridge cover Removing Removing and installing left Removing and installing front mudguard Removing and installing front mudguard front sect... Removing and installing front mudguard rear secti... Removing and installing front footrests Removing and installing front right footrest plate... Removing and installing front left footrest plate Removing gearshift lever Removing and installing left Removing and installing rear footrests Disassembling rear footrest Disassembling and assembling side stand Removing and installing main (centre) stand See Group 00, Lubricating main stand Removing and installing intake air pipe Removing and installing skirt bracket Removing and installing crash bar Removing and installing radiator holder Removing and installing rear- mounted components Removing and installing number-plate carrier Removing and installing top case Additional instructions for moving the backrest Disassembling top case Removing Removing mirror and document stowage compartment Removing lid of top case Removing base of top case Removing and installing rear carrier cover Removing and installing case trimmer Removing and installing side case Removing and installing side case lid Removing and installing rear moulding Removing and installing rear carrier section Removing rear mudguard Removing and installing front fairing bracket Removing reflectors Removing upper reflector Removing lower reflector Removing and installing retaining plates in front ... Checking running gear Measuring wheel track offset Example Checking the leading link for deformation See Group 31 Removing and installing frame Removing and installing rear frame Removing and installing cross-tube Preparatory work Additional preparations for removing engine, gearb... Removing and installing cross-tube Removing and installing left Removing main frame Installing main frame 51 Equipment Removing and installing ignition switch Removing and installing lock barrel Removing the lock barrel Removing lock barrel if ignition key has broken of... Installing lock barrel Disassembling Removing and installing flap for tank cap Removing and installing snap lock for tank cap fla... Removing and installing fuel tank lock barrel Removing and installing lock barrel of fuel tank c... Removing and installing locking system for front s... Removing locking system Removing and installing Bowden release cable Removing and installing lock barrel of side case Removing and installing lock barrel of top case 52 Seat Removing and installing seat Removing and installing front seat with bridge Removing and installing rear seat Removing and installing rear seat backrest Disassembling Removing and installing front seat Removing and installing gas-filled strut 61 General electrical equipment Wiring harness View from right View from left Rear frame wiring harness Top case wiring Tank cover with radio Connectors beside ABS control unit Connectors on fairing bracket Relay positions in electronics box Connectors, electronics box Handlebar wiring Replacing fuses Motorcycle fuses Fuses Fuse for radio Removing and installing electronics box Disassembling left multi-function switch Preparatory work Removing and installing radio control unit Removing and installing clutch switch Removing left multi-function switch Disassembling right multi-function switch Removing and installing right multi-function switc... Removing brake light switch Removing and installing control unit for reverser Removing and installing inductive sensor for speed... Removing and installing water temperature sensor Replacing side stand switch Removing and installing side stand switch Check operation of side stand switch Replacing and adjusting foot brake light switch Removing and installing brake light switch Adjusting brake light switch Removing and installing ignition switch Removing and installing fanfare horn Removing and installing switch for gear indicator Removing and installing power socket Socket on engine spoiler Socket in top case Removing and installing cable for oil pressure swi... Removing cables Installing cables Removing and installing battery See Group 00, Battery Removing and installing battery carrier See Group34, Removing ABS control unit Removing and installing front and rear ABS sensors... See Group 34 62 Instruments Wiring colours Removing and installing instrument panel Replacing telltale Telltale Disassembling instrument cluster Removing speedometer, rev. counter, temperature ga... Removing clock Removing and installing wiring harness 63 Lights Removing and installing headlight Renewing bulbs Bulb for low-beam headlight Low (dipped) beam headlight High (main) beam headlight Bulb, parking light Front turn signal Rear lights Checking headlight beam angle, adjusting if necess... Vertical adjustment Lateral adjustment 65 Radio and optional extras Removing and installing speakers Front speakers Preparatory work Treble speaker Bass speaker Loudspeaker box Rear speakers Removing and installing radio Preparatory work Removing radio control unit Removing radio Removing and installing radio remote control unit Removing and installing front radio remote control... See Group 61, Removing and installing radio contro... Removing and installing rear radio remote control ... Removing and installing aerial holder Removing and installing on-board computer Removing and installing temperature sensor on upp... Removing and installing control unit of cruise-con... . Notice: This is a preview not fully updated, please download the full version at https://wimanual.com