BMW K1200LT K 1200 LT 2002 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: K1200LT Model Designation: K 1200 LT Year: 2002 Generation Generation Code: 1st Generation K1200LT Codes Chassis Code: K589 👋 Introduction Market Position Market Segment: Luxury Grand Tourer Motorcycle Target Audience: Touring enthusiasts seeking comfort, performance, and long-distance capability, as well as owners and technicians performing maintenance and repairs. Competitive Analysis Key Competitors: Honda Gold Wing, Harley-Davidson Electra Glide, Yamaha Royal Star Venture Key Features Unique Selling Points: Long-distance comfort, sophisticated technology for its era, BMW's renowned engineering, powerful inline-four engine, integrated luggage, reverse gear (on some models/years). Manual Value Proposition: Provides the complete, authoritative technical documentation necessary for maintaining and repairing the K1200LT to factory standards, ensuring optimal performance and longevity. 📋 Manual Details Coverage Areas Systems Covered: Engine, Fuel System, Ignition, Clutch, Transmission, Final Drive, Suspension, Brakes, Electrical System, Bodywork, Chassis, Diagnostics, Troubleshooting, Maintenance Page Count Page Count Estimated: Hundreds of pages Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, inspection, and reassembly procedures for the inline four-cylinder engine, including valve timing, piston and cylinder inspection, crankshaft and connecting rod checks. Fuel System: Comprehensive coverage of the fuel injection system, including fuel pump diagnosis, injector testing, throttle body calibration, and evaporative emission control system. Ignition System: Detailed information on the electronic ignition system, including ignition coil testing, spark plug specifications, and troubleshooting ignition timing issues. Clutch System: Procedures for clutch inspection, adjustment, and replacement of clutch components for the hydraulic clutch system. Transmission And Drivetrain: Detailed instructions for transmission disassembly, gear inspection, shift mechanism repair, and final drive unit maintenance, including shaft and bearing checks. Suspension System: Front and rear suspension component inspection, adjustment, and repair, including fork seal replacement, shock absorber servicing, and linkage checks. Brake System: Detailed procedures for brake caliper overhaul, master cylinder inspection, ABS system diagnostics and troubleshooting, fluid flushing, and pad/rotor replacement. Electrical System: Extensive wiring diagrams, component testing procedures for starter motor, alternator, battery, lighting systems, instrument cluster, and electronic control units (ECU). Bodywork And Frame: Procedures for fairing removal and installation, seat adjustments, luggage system maintenance, and minor body panel repair. Chassis And Steering: Headstock bearing inspection and replacement, steering alignment checks, and wheel bearing maintenance. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, chain/drive shaft lubrication, brake fluid checks, tire pressure adjustments, and coolant level checks. Troubleshooting Diagnostics: Systematic diagnostic charts and procedures for identifying and resolving common and uncommon mechanical and electrical issues, including fault code interpretation. Repair Rebuild: Step-by-step instructions for component repair and complete system rebuilds, from engine internals to suspension linkages and electrical components. Adjustment Calibration: Procedures for adjusting clutch, throttle cables, suspension settings, and calibrating electronic systems like ABS and fuel injection. Component Replacement: Detailed guides for replacing wear items such as brake pads, tires, batteries, filters, and more specialized components like wheel bearings and drive shaft U-joints. Technical Depth Depth Level: Comprehensive, factory-level technical information suitable for professional mechanics and advanced DIY enthusiasts. Diagnostic Tools: Includes information on specialized tools and diagnostic equipment required for specific procedures and fault finding. Torque Specifications: Detailed torque specifications for all fasteners throughout the motorcycle, crucial for proper assembly and safety. Clearances Tolerances: Essential service limits and tolerances for critical engine and drivetrain components to ensure proper operation and longevity. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Print Quality Printability: Printable, allowing for individual page printing or complete manual output. Binding Type Binding Type For Print: Not applicable (digital download), but designed for standard binding methods (e.g., comb, spiral, binder). Paper Type Paper Type For Print: Not applicable (digital download), but typical recommendations would be durable, high-quality paper suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, inline four-cylinder Displacement: 1171 cc (71.6 cu in) Bore X Stroke: 78.8 mm x 61.8 mm Compression Ratio: 10.0:1 Valvetrain: DOHC, 4 valves per cylinder Performance Horsepower Max: 100 hp (74 kW) at 6750 rpm (approximate) Torque Max: 115 Nm (85 lb-ft) at 5250 rpm (approximate) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Bosch Motronic MA 2.4 Fuel Type: Unleaded Premium Gasoline (95 RON recommended) Ignition Ignition System: Electronic ignition with dual spark plugs per cylinder Cooling System Cooling Method: Liquid-cooled Lubrication Oil Capacity With Filter: 4.5 Liters (4.8 US qt) Oil Type Recommended: SAE 20W-40 or 20W-50 Motorcycle Oil (API SG or higher) 🔧 Transmission Standard Transmission Type: 5-speed manual Clutch Type: Hydraulic, multi-disc wet clutch Final Drive: Shaft drive Features Reverse Gear: Electric reverse gear (standard on most K1200LT models) Maintenance Transmission Oil Type: BMW Special Gear Oil (GL-5, SAE 75W-90) Transmission Oil Capacity: 0.3 Liters (0.32 US qt) 📐 Dimensions Exterior Length: 2400 mm (94.5 in) Width: 970...
Touring enthusiasts seeking comfort, performance, and long-distance capability, as well as owners and technicians performing maintenance and repairs.
Competitive Analysis
Key Competitors:
Honda Gold Wing, Harley-Davidson Electra Glide, Yamaha Royal Star Venture
Key Features
Unique Selling Points:
Long-distance comfort, sophisticated technology for its era, BMW's renowned engineering, powerful inline-four engine, integrated luggage, reverse gear (on some models/years).
Manual Value Proposition:
Provides the complete, authoritative technical documentation necessary for maintaining and repairing the K1200LT to factory standards, ensuring optimal performance and longevity.
Detailed disassembly, inspection, and reassembly procedures for the inline four-cylinder engine, including valve timing, piston and cylinder inspection, crankshaft and connecting rod checks.
Fuel System:
Comprehensive coverage of the fuel injection system, including fuel pump diagnosis, injector testing, throttle body calibration, and evaporative emission control system.
Ignition System:
Detailed information on the electronic ignition system, including ignition coil testing, spark plug specifications, and troubleshooting ignition timing issues.
Clutch System:
Procedures for clutch inspection, adjustment, and replacement of clutch components for the hydraulic clutch system.
Transmission And Drivetrain:
Detailed instructions for transmission disassembly, gear inspection, shift mechanism repair, and final drive unit maintenance, including shaft and bearing checks.
Suspension System:
Front and rear suspension component inspection, adjustment, and repair, including fork seal replacement, shock absorber servicing, and linkage checks.
Brake System:
Detailed procedures for brake caliper overhaul, master cylinder inspection, ABS system diagnostics and troubleshooting, fluid flushing, and pad/rotor replacement.
Electrical System:
Extensive wiring diagrams, component testing procedures for starter motor, alternator, battery, lighting systems, instrument cluster, and electronic control units (ECU).
Bodywork And Frame:
Procedures for fairing removal and installation, seat adjustments, luggage system maintenance, and minor body panel repair.
Chassis And Steering:
Headstock bearing inspection and replacement, steering alignment checks, and wheel bearing maintenance.
Systematic diagnostic charts and procedures for identifying and resolving common and uncommon mechanical and electrical issues, including fault code interpretation.
Repair Rebuild:
Step-by-step instructions for component repair and complete system rebuilds, from engine internals to suspension linkages and electrical components.
Adjustment Calibration:
Procedures for adjusting clutch, throttle cables, suspension settings, and calibrating electronic systems like ABS and fuel injection.
Component Replacement:
Detailed guides for replacing wear items such as brake pads, tires, batteries, filters, and more specialized components like wheel bearings and drive shaft U-joints.
Technical Depth
Depth Level:
Comprehensive, factory-level technical information suitable for professional mechanics and advanced DIY enthusiasts.
Diagnostic Tools:
Includes information on specialized tools and diagnostic equipment required for specific procedures and fault finding.
Torque Specifications:
Detailed torque specifications for all fasteners throughout the motorcycle, crucial for proper assembly and safety.
Clearances Tolerances:
Essential service limits and tolerances for critical engine and drivetrain components to ensure proper operation and longevity.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval.
Print Quality
Printability:
Printable, allowing for individual page printing or complete manual output.
Binding Type
Binding Type For Print:
Not applicable (digital download), but designed for standard binding methods (e.g., comb, spiral, binder).
Paper Type
Paper Type For Print:
Not applicable (digital download), but typical recommendations would be durable, high-quality paper suitable for workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, inline four-cylinder
Displacement:
1171 cc (71.6 cu in)
Bore X Stroke:
78.8 mm x 61.8 mm
Compression Ratio:
10.0:1
Valvetrain:
DOHC, 4 valves per cylinder
Performance
Horsepower Max:
100 hp (74 kW) at 6750 rpm (approximate)
Torque Max:
115 Nm (85 lb-ft) at 5250 rpm (approximate)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Bosch Motronic MA 2.4
Fuel Type:
Unleaded Premium Gasoline (95 RON recommended)
Ignition
Ignition System:
Electronic ignition with dual spark plugs per cylinder
Cooling System
Cooling Method:
Liquid-cooled
Lubrication
Oil Capacity With Filter:
4.5 Liters (4.8 US qt)
Oil Type Recommended:
SAE 20W-40 or 20W-50 Motorcycle Oil (API SG or higher)
🔧 Transmission
Standard
Transmission Type:
5-speed manual
Clutch Type:
Hydraulic, multi-disc wet clutch
Final Drive:
Shaft drive
Features
Reverse Gear:
Electric reverse gear (standard on most K1200LT models)
Maintenance
Transmission Oil Type:
BMW Special Gear Oil (GL-5, SAE 75W-90)
Transmission Oil Capacity:
0.3 Liters (0.32 US qt)
📐 Dimensions
Exterior
Length:
2400 mm (94.5 in)
Width:
970 mm (38.2 in)
Height:
1430 mm (56.3 in) (seat height adjustable)
Wheelbase:
1625 mm (64.0 in)
Weights
Dry Weight Estimated:
337 kg (743 lbs)
Gross Vehicle Weight Rating:
570 kg (1257 lbs)
Fuel Tank Capacity:
21 Liters (5.5 US gal), including 3.5L reserve
Chassis And Suspension
Front Suspension:
BMW Telelever
Rear Suspension:
Paralever single-sided swingarm with central spring strut
Front Wheel Travel:
115 mm (4.5 in)
Rear Wheel Travel:
130 mm (5.1 in)
Wheels And Tires
Front Tire Size:
120/70 ZR17
Rear Tire Size:
170/80 ZR15
Front Wheel Type:
Cast aluminum alloy
Rear Wheel Type:
Cast aluminum alloy, single-sided swingarm
Wheelbase Bolt Pattern:
5 x 112 mm (typical for BMW automobiles, but specific for motorcycle hubs)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Motorcycle safety ratings are not typically standardized in the same way as automobiles. Focus is on engineering and rider aids.
Active Features
ABS System:
BMW Integral ABS (optional on some models, standard on later ones; includes linked braking)
Linked Braking:
Brake lever actuates both front and rear brakes (with ABS integration)
Some owners have reported issues with the ABS modulator, starter solenoids, and general electrical connections due to vibration and age.
Engine Specific Notes:
Regular valve adjustments and proper coolant levels are crucial for longevity. The engine is robust but requires diligent maintenance.
Fuel System Notes:
Keep fuel injectors clean and use high-quality fuel to prevent performance issues. Check fuel pump operation as per manual procedures.
📚 Vehicle History
Brand Heritage
Brand History:
BMW Motorrad, a division of Bayerische Motoren Werke AG, has a long and distinguished history in motorcycle design and manufacturing, dating back to the 1920s.
Model Evolution
K Series Introduction:
The K series, introduced in the early 1980s, marked BMW's foray into multi-cylinder, fuel-injected motorcycles, evolving from inline-fours to inline-threes and inline-sixes.
K1200Lt Development:
The K1200LT succeeded the K1100LT, representing BMW's flagship touring motorcycle, emphasizing comfort, technology, and performance for extended journeys.
Production
Production Period K1200Lt:
1997-2008 (with significant updates and variations between model years)
Manufacturing Location:
Berlin, Germany (Spandau plant)
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The K1200LT was widely praised for its comfort and touring capabilities, earning it a reputation as a premier grand tourer in its class during its production run.
Ratings
Owner Satisfaction:
Generally high owner satisfaction for long-distance comfort and reliability when properly maintained.
Certifications
Emission Standards:
Meets relevant emissions standards for its production year; manual will detail specific catalytic converter and emissions control system maintenance.
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