BMW K1200 K12000LT Motorcycle Complete Workshop Service Repair Manual 1997 1998 1999 2000 2001 2002 2003 2004
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🏷️ Basic Information Identification Make: BMW Model: K1200LT Model Nickname: The King of the Road Vehicle Type: Touring Motorcycle Generation Covered Years: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Codes Chassis Code: K589 👋 Introduction Market Position Segment: Luxury Grand Touring Motorcycle Target Audience: Long-distance touring riders, demanding comfort, performance, and versatility. Competitive Analysis Key Competitors: Honda Gold Wing, Harley-Davidson Electra Glide, Kawasaki Voyager, Yamaha Venture Key Features Touring Amenities: Aerodynamic fairing with integrated wind deflector, large comfortable seat, integrated audio system, ample luggage capacity (saddlebags, top case), cruise control. Engineering Excellence: BMW's renowned Boxer engine (though K1200LT uses inline-four), shaft drive, Telelever front suspension (on later models, though K1200LT uses conventional telescopic), Paralever rear suspension, advanced ABS braking. Manual Value Proposition Benefit To Owner: Empowers owners to perform routine maintenance, troubleshoot issues, and undertake repairs, saving money and ensuring optimal performance and longevity of their valuable motorcycle. 📋 Manual Details Coverage Areas Primary Focus: Comprehensive Service, Repair, and Maintenance Systems Addressed: Engine, Fuel System, Ignition System, Transmission, Clutch, Drivetrain, Suspension, Brakes, Electrical System, Bodywork, Fairings, Controls, Instruments, Diagnostic Procedures Page Count Estimated Pages: 700+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital Downloadable (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, assembly, inspection, and repair of engine components including cylinder head, valves, crankshaft, pistons, connecting rods, timing chain, oil pump. Fuel System: Fuel injection system (Bosch Motronic), fuel pump, injectors, fuel filter replacement, fuel tank maintenance, pressure testing. Ignition System: Ignition coil testing, spark plug replacement, ECU diagnostics, sensor testing (crankshaft position, camshaft position). Transmission Clutch: Clutch inspection, adjustment, replacement. Gearbox disassembly, assembly, inspection of gears, shafts, and bearings. Shift mechanism repair. Drivetrain: Final drive inspection, maintenance, and repair. Driveshaft and universal joint servicing. Wheel bearing replacement. Suspension Steering: Front fork (Telescopic) disassembly, seal replacement, oil change. Rear monoshock absorber inspection and replacement. Steering head bearing maintenance. Wheel alignment. Brakes: ABS II system diagnostics and repair. Brake fluid flush and bleeding procedures. Caliper overhaul, pad replacement, rotor inspection. Parking brake mechanism. Electrical System: Battery testing and replacement. Charging system (alternator, voltage regulator). Starter motor. Lighting system (headlights, taillights, turn signals). Horn. Wiring diagrams and troubleshooting guides. Instrument cluster diagnostics. Bodywork Fairings: Fairing removal and installation. Seat adjustment and removal. Luggage systems (top case, saddlebags) mounting and repair. Windscreen adjustment and replacement. Controls Instruments: Handlebar and lever adjustments. Throttle and clutch cable replacement. Cruise control system troubleshooting. Dashboard indicator lights and warning messages. Procedures Included Scheduled Maintenance: Detailed service schedules for oil changes, filter replacements, chain lubing, brake checks, and other routine maintenance tasks at specific mileage or time intervals. Troubleshooting: Systematic diagnostic procedures for identifying and resolving common and uncommon problems, including fault codes and symptom-based troubleshooting trees. Disassembly Assembly: Step-by-step instructions with detailed diagrams for the complete disassembly and reassembly of all major motorcycle components and systems. Repair Rebuild: In-depth guidance on the repair and rebuilding of worn or damaged parts, including specifications for machining and tolerances. Special Tools: Identification and usage instructions for specialized tools required for specific repair and maintenance procedures. Technical Depth Depth: Comprehensive: Covers everything from basic checks and fluid changes to full engine rebuilds, electrical system diagnostics, and advanced troubleshooting. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text content for quick access to specific information Readability: High-resolution scanned pages for clear text and legible diagrams Printability: Printable pages for physical reference Print Quality Quality Notes: Digital reproduction, quality dependent on original source scan. Binding Type Binding Notes: Not applicable for digital format; printable for user binding. Paper Type Paper Notes: Not applicable for digital format; recommend durable paper for printing. ⚙️ Engine Specifications Primary Engine Configuration: Inline-four cylinder Displacement: 1171 cc (for K1200LT pre-2004) Bore X Stroke: 70.5 mm x 75 mm Valve Train: DOHC, 4 valves per cylinder Cooling System: Liquid-cooled Performance Horsepower: 100-107 hp (approx. depending on year and tuning) Torque: 80-85 lb-ft (approx. depending on year and tuning) Fuel System Induction: Electronic Fuel Injection (EFI) - Bosch Motronic MA 2.4 or similar Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/2) Fluid Capacities Engine Oil Capacity: Approx. 4.5 liters (4.8 US quarts) with filter change Coolant Capacity: Approx. 2.5 liters (2.6 US quarts) 🔧 Transmission Standard Type: 5-speed manual Clutch: Hydraulically actuated, multi-plate wet clutch Final Drive: Shaft drive Features Gear Ratios: Specific ratios provided in manual Transmission Fluid Type: Hypoid gear oil, API GL-5, SAE 80W/90 📐 Dimensions Exterior Length: Approx. 2400 mm (94.5 in) Width: Approx. 930 mm (36.6 in) Height: Approx. 1600 mm (63.0 in) Wheelbase: Approx. 1570 mm (61.8 in) Weights Dry Weight: Approx. 295 kg (650 lbs) Wet Weight: Approx. 330 kg (727 lbs) Max Load: Approx. 220 kg (485 lbs) Cargo Saddlebag Capacity: Integrated, approximately 32 liters each Top Case Capacity: Integrated, approximately 55 liters...
Aerodynamic fairing with integrated wind deflector, large comfortable seat, integrated audio system, ample luggage capacity (saddlebags, top case), cruise control.
Engineering Excellence:
BMW's renowned Boxer engine (though K1200LT uses inline-four), shaft drive, Telelever front suspension (on later models, though K1200LT uses conventional telescopic), Paralever rear suspension, advanced ABS braking.
Manual Value Proposition
Benefit To Owner:
Empowers owners to perform routine maintenance, troubleshoot issues, and undertake repairs, saving money and ensuring optimal performance and longevity of their valuable motorcycle.
Clutch inspection, adjustment, replacement. Gearbox disassembly, assembly, inspection of gears, shafts, and bearings. Shift mechanism repair.
Drivetrain:
Final drive inspection, maintenance, and repair. Driveshaft and universal joint servicing. Wheel bearing replacement.
Suspension Steering:
Front fork (Telescopic) disassembly, seal replacement, oil change. Rear monoshock absorber inspection and replacement. Steering head bearing maintenance. Wheel alignment.
Brakes:
ABS II system diagnostics and repair. Brake fluid flush and bleeding procedures. Caliper overhaul, pad replacement, rotor inspection. Parking brake mechanism.
Electrical System:
Battery testing and replacement. Charging system (alternator, voltage regulator). Starter motor. Lighting system (headlights, taillights, turn signals). Horn. Wiring diagrams and troubleshooting guides. Instrument cluster diagnostics.
Bodywork Fairings:
Fairing removal and installation. Seat adjustment and removal. Luggage systems (top case, saddlebags) mounting and repair. Windscreen adjustment and replacement.
Controls Instruments:
Handlebar and lever adjustments. Throttle and clutch cable replacement. Cruise control system troubleshooting. Dashboard indicator lights and warning messages.
Procedures Included
Scheduled Maintenance:
Detailed service schedules for oil changes, filter replacements, chain lubing, brake checks, and other routine maintenance tasks at specific mileage or time intervals.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and uncommon problems, including fault codes and symptom-based troubleshooting trees.
Disassembly Assembly:
Step-by-step instructions with detailed diagrams for the complete disassembly and reassembly of all major motorcycle components and systems.
Repair Rebuild:
In-depth guidance on the repair and rebuilding of worn or damaged parts, including specifications for machining and tolerances.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair and maintenance procedures.
Technical Depth
Depth:
Comprehensive: Covers everything from basic checks and fluid changes to full engine rebuilds, electrical system diagnostics, and advanced troubleshooting.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text content for quick access to specific information
Readability:
High-resolution scanned pages for clear text and legible diagrams
Printability:
Printable pages for physical reference
Print Quality
Quality Notes:
Digital reproduction, quality dependent on original source scan.
Binding Type
Binding Notes:
Not applicable for digital format; printable for user binding.
Paper Type
Paper Notes:
Not applicable for digital format; recommend durable paper for printing.
⚙️ Engine Specifications
Primary Engine
Configuration:
Inline-four cylinder
Displacement:
1171 cc (for K1200LT pre-2004)
Bore X Stroke:
70.5 mm x 75 mm
Valve Train:
DOHC, 4 valves per cylinder
Cooling System:
Liquid-cooled
Performance
Horsepower:
100-107 hp (approx. depending on year and tuning)
Torque:
80-85 lb-ft (approx. depending on year and tuning)
Fuel System
Induction:
Electronic Fuel Injection (EFI) - Bosch Motronic MA 2.4 or similar
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2)
Fluid Capacities
Engine Oil Capacity:
Approx. 4.5 liters (4.8 US quarts) with filter change
Coolant Capacity:
Approx. 2.5 liters (2.6 US quarts)
🔧 Transmission
Standard
Type:
5-speed manual
Clutch:
Hydraulically actuated, multi-plate wet clutch
Final Drive:
Shaft drive
Features
Gear Ratios:
Specific ratios provided in manual
Transmission Fluid Type:
Hypoid gear oil, API GL-5, SAE 80W/90
📐 Dimensions
Exterior
Length:
Approx. 2400 mm (94.5 in)
Width:
Approx. 930 mm (36.6 in)
Height:
Approx. 1600 mm (63.0 in)
Wheelbase:
Approx. 1570 mm (61.8 in)
Weights
Dry Weight:
Approx. 295 kg (650 lbs)
Wet Weight:
Approx. 330 kg (727 lbs)
Max Load:
Approx. 220 kg (485 lbs)
Cargo
Saddlebag Capacity:
Integrated, approximately 32 liters each
Top Case Capacity:
Integrated, approximately 55 liters
🛡️ Safety Features
Ratings
ABS:
BMW Motorrad Integral ABS II (standard)
Active Features
Braking System:
Dual front disc brakes (305 mm), single rear disc brake (285 mm) with multi-piston calipers.
Lighting:
Halogen headlights, multi-reflector design, LED taillight.
Passive Features
Frame Construction:
Aluminum composite bridge frame
Ride Comfort:
Designed for long-distance comfort, reducing rider fatigue.
💡 Technology Features
Infotainment
Audio System:
Integrated multi-speaker audio system, often with CD player or radio tuner. Cassette player on early models.
Cruise Control:
Electronic cruise control system
Driver Assistance
ABS:
BMW Motorrad Integral ABS II (standard on all covered models), combining brake and clutch levers to activate front and rear brakes.
Connectivity
Diagnostic Interface:
On-board diagnostics (OBD) port for electronic fault detection and analysis, with specific BMW diagnostic tools mentioned.
Convenience Features
Heated Grips Seats:
Standard feature on most K1200LT models, offering adjustable heating levels.
Reverse Gear:
Electric reverse gear (standard on K1200LT), powered by the starter motor.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,000 miles) or annually, whichever comes first.
Air Filter Replacement:
Every 20,000 km (12,000 miles)
Spark Plug Replacement:
Every 20,000 km (12,000 miles)
Brake Fluid Change:
Every 2 years (regardless of mileage)
Coolant Change:
Every 3-4 years or as specified
Fluid Specifications
Engine Oil Specification:
API SG or higher, SAE 20W-40 or 20W-50 (depending on climate). Refer to manual for specific recommendations.
Brake Fluid Specification:
DOT 4
Coolant Specification:
BMW approved ethylene glycol coolant mixture (typically 50/50 with distilled water)
Potential for intermittent electrical issues, particularly related to the complex wiring harness and integrated systems.
Heating Elements:
Heated grips and seat elements can be prone to failure over time.
Transmission Noise:
Some models may exhibit normal transmission whine; distinguishing it from abnormal noise is crucial and covered in the manual.
📚 Vehicle History
Brand Heritage
Manufacturer:
Bayerische Motoren Werke AG (BMW)
Heritage Focus:
Innovation in motorcycle engineering, known for Boxer engines, shaft drive, and rider-focused design.
Model Evolution
K Series Origin:
The K series, introduced in the early 1980s, marked BMW's move to inline-four engines, offering smoother power delivery compared to their traditional boxer twins.
K1200Lt Development:
The K1200LT was developed from the K1100LT, focusing on enhanced touring capabilities, comfort, and integrated amenities, becoming BMW's flagship touring machine.
Production
Production Start:
1997
Production End For This Manual:
2004
Manufacturing Location:
Berlin, Germany
Model Updates Within Period
Key Changes 97-04:
Minor updates to electronics, ABS system improvements, potential styling tweaks, and power output adjustments across the model years.
🏆 Awards & Recognition
Recognitions
Bike Magazine Reviews:
Consistently praised by motorcycle publications for its comfort, handling, and touring capability.
Long Term Test Results:
Often featured in long-term tests highlighting its durability and suitability for extended journeys.
Ratings
Customer Satisfaction:
High customer satisfaction for its intended purpose as a premier touring motorcycle.