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BMW K1200 K1200LT 2003 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: K1200LT Year: 2003 Codes Chassis Code: K589 👋 Introduction Market Position Segment: Luxury Touring Motorcycle Target Audience: Touring enthusiasts seeking comfort, features, and performance for long-distance riding. Competitive Analysis Competitors: Honda Gold Wing, Harley-Davidson Electra Glide, Yamaha Royal Star Venture, Kawasaki Voyager. Key Features Design Philosophy: BMW's emphasis on engineering excellence, rider comfort, and integrated technology for grand touring. Model Distinction: Known for its powerful engine, advanced features for its time, and exceptional comfort for rider and passenger on long journeys. 📋 Manual Details Coverage Areas Coverage: Complete service, repair, diagnostics, and maintenance for the BMW K1200LT 2003 model. Page Count Page Count: Extensive (typically 500+ pages for comprehensive manuals of this type, exact count not specified in product info) Manual Type Manual Type: Service Repair Workshop Manual Language Language: English Format Format: Likely PDF, Digital Download (typical for workshop manuals of this nature) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, troubleshooting, cylinder head, pistons, crankshaft, camshafts, valve train, oil system. Fuel System: Fuel injection system (EFI), fuel pump, injectors, fuel lines, fuel tank, throttle body, sensors (TPS, MAP, IAT), emissions control. Ignition System: Ignition coils, spark plugs, ECU control, timing. Cooling System: Radiator, coolant pump, thermostat, hoses, fan, coolant specifications. Transmission: Clutch operation and adjustment, gearbox internals, shift mechanism, transmission fluid specifications and change intervals. Drivetrain: Shaft drive system, final drive unit, driveshaft, universal joints, lubrication. Brakes System: Hydraulic brake system, ABS (Anti-lock Braking System), brake fluid specifications, caliper maintenance, rotor inspection, brake line replacement, bleeding procedures. Suspension System: Front forks (telescopic, possibly with electronic adjustment), rear shock absorber, linkage, spring rates, damping adjustments, fluid specifications for forks. Steering System: Handlebar assembly, steering head bearings, steering stem, adjustments, lubrication. Electrical System: Battery, charging system (alternator/generator), starter motor, lighting (headlight, taillight, turn signals), wiring diagrams, fuses, relays, ECU, diagnostics (OBD). Bodywork And Trim: Fairings, body panels, seat assembly, luggage systems (top case, saddlebags), instrumentation, mirrors, windshield adjustment/replacement. Chassis And Frame: Frame inspection, swingarm, wheel bearings, alignment, torque specifications for fasteners. Diagnostics Diagnostic Troubleshooting: Systematic diagnostic procedures for common faults and error codes, using specialized tools (if applicable). Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, chain/shaft drive lubrication and adjustment, brake fluid flush, coolant flush. Major Repairs: Engine rebuilds, transmission overhaul, suspension component replacement, electrical system repairs, bodywork refinishing. Troubleshooting Guides: Step-by-step guides to identify and resolve specific performance issues and malfunctions. Electrical Troubleshooting: Schematic interpretation, testing of sensors, actuators, and wiring harnesses. Technical Depth Depth: Comprehensive coverage suitable for professional mechanics and advanced DIY enthusiasts, including detailed torque specifications, tolerances, and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) - Assumed for ease of distribution and searchability. Searchability: Likely text-searchable for quick access to information. Print Quality Print Quality: Designed for clear reproduction in print, featuring legible diagrams and text. Binding Type Binding Type: N/A (Digital Format) - If printed, typically spiral-bound or perfect-bound for workshop use. Paper Type Paper Type: N/A (Digital Format) - If printed, would typically be on durable, matte-finish paper for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, 4-stroke Displacement: 1171 cc Bore X Stroke: 79 mm x 59 mm Compression Ratio: 10.0:1 Valve Train: DOHC (Double Overhead Camshaft), 4 valves per cylinder Cooling System: Liquid-cooled Performance Horsepower: Approx. 98 hp @ 7500 rpm (specification varies slightly by region and tuning) Torque: Approx. 117 Nm (86 lb-ft) @ 5200 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Bosch Motronic engine management. Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/2) Oil System Oil Capacity: Approx. 4.0 liters (4.2 US quarts) with filter change. Recommended Oil Type: API SG/SH/SJ, ACEA A2/A3, SAE 5W-40 or 10W-40 Synthetic Motorcycle Oil. 🔧 Transmission Standard Transmission Type: 5-speed manual gearbox with integral clutch. Features Clutch Type: Hydraulically operated multi-plate wet clutch. Final Drive: Shaft drive Fluid Specifications Transmission Oil Type: SAE 75W-90 GL-5 gear oil (BMW recommends specific grades, manual will detail). Fluid Capacity Transmission Oil Capacity: Approximately 0.5 liters (0.53 US quarts). 📐 Dimensions Exterior Length: Approx. 2430 mm (95.7 in) Width: Approx. 960 mm (37.8 in) at handlebars Height: Approx. 1580 mm (62.2 in) at windshield Weights Dry Weight: Approx. 330 kg (728 lbs) Gross Vehicle Weight Rating: Approx. 540 kg (1190 lbs) Wheelbase Wheelbase: Approx. 1629 mm (64.1 in) Seat Height Seat Height: Approx. 790 mm (31.1 in) 🛡️ Safety Features Ratings ABS: Integral ABS (often BMW's EVO ABS system). Active Features Braking System: Dual front disc brakes, single rear disc brake. ABS system for enhanced control. Lighting: Halogen headlight, LED taillight, integrated turn signals. Passive Features Frame Design: Sturdy aluminum frame providing rigidity and stability. Wind Protection: Large aerodynamic fairing and adjustable windshield for rider comfort and protection. 💡...
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BMW K1200 K1200LT 2003 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
K1200LT
Year:
2003
Codes
Chassis Code:
K589
👋 Introduction
Market Position
Segment:
Luxury Touring Motorcycle
Target Audience:
Touring enthusiasts seeking comfort, features, and performance for long-distance riding.
Competitive Analysis
Competitors:
Honda Gold Wing, Harley-Davidson Electra Glide, Yamaha Royal Star Venture, Kawasaki Voyager.
Key Features
Design Philosophy:
BMW's emphasis on engineering excellence, rider comfort, and integrated technology for grand touring.
Model Distinction:
Known for its powerful engine, advanced features for its time, and exceptional comfort for rider and passenger on long journeys.
📋 Manual Details
Coverage Areas
Coverage:
Complete service, repair, diagnostics, and maintenance for the BMW K1200LT 2003 model.
Page Count
Page Count:
Extensive (typically 500+ pages for comprehensive manuals of this type, exact count not specified in product info)
Manual Type
Manual Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Likely PDF, Digital Download (typical for workshop manuals of this nature)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, inspection, troubleshooting, cylinder head, pistons, crankshaft, camshafts, valve train, oil system.
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, fuel lines, fuel tank, throttle body, sensors (TPS, MAP, IAT), emissions control.
Ignition System:
Ignition coils, spark plugs, ECU control, timing.
Cooling System:
Radiator, coolant pump, thermostat, hoses, fan, coolant specifications.
Transmission:
Clutch operation and adjustment, gearbox internals, shift mechanism, transmission fluid specifications and change intervals.
Drivetrain:
Shaft drive system, final drive unit, driveshaft, universal joints, lubrication.
Brakes System:
Hydraulic brake system, ABS (Anti-lock Braking System), brake fluid specifications, caliper maintenance, rotor inspection, brake line replacement, bleeding procedures.
Suspension System:
Front forks (telescopic, possibly with electronic adjustment), rear shock absorber, linkage, spring rates, damping adjustments, fluid specifications for forks.
Steering System:
Handlebar assembly, steering head bearings, steering stem, adjustments, lubrication.
Electrical System:
Battery, charging system (alternator/generator), starter motor, lighting (headlight, taillight, turn signals), wiring diagrams, fuses, relays, ECU, diagnostics (OBD).
Bodywork And Trim:
Fairings, body panels, seat assembly, luggage systems (top case, saddlebags), instrumentation, mirrors, windshield adjustment/replacement.
Chassis And Frame:
Frame inspection, swingarm, wheel bearings, alignment, torque specifications for fasteners.
Diagnostics
Diagnostic Troubleshooting:
Systematic diagnostic procedures for common faults and error codes, using specialized tools (if applicable).
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, chain/shaft drive lubrication and adjustment, brake fluid flush, coolant flush.
Major Repairs:
Engine rebuilds, transmission overhaul, suspension component replacement, electrical system repairs, bodywork refinishing.
Troubleshooting Guides:
Step-by-step guides to identify and resolve specific performance issues and malfunctions.
Electrical Troubleshooting:
Schematic interpretation, testing of sensors, actuators, and wiring harnesses.
Technical Depth
Depth:
Comprehensive coverage suitable for professional mechanics and advanced DIY enthusiasts, including detailed torque specifications, tolerances, and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format) - Assumed for ease of distribution and searchability.
Searchability:
Likely text-searchable for quick access to information.
Print Quality
Print Quality:
Designed for clear reproduction in print, featuring legible diagrams and text.
Binding Type
Binding Type:
N/A (Digital Format) - If printed, typically spiral-bound or perfect-bound for workshop use.
Paper Type
Paper Type:
N/A (Digital Format) - If printed, would typically be on durable, matte-finish paper for workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, 4-stroke
Displacement:
1171 cc
Bore X Stroke:
79 mm x 59 mm
Compression Ratio:
10.0:1
Valve Train:
DOHC (Double Overhead Camshaft), 4 valves per cylinder
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approx. 98 hp @ 7500 rpm (specification varies slightly by region and tuning)
Torque:
Approx. 117 Nm (86 lb-ft) @ 5200 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Bosch Motronic engine management.
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2)
Oil System
Oil Capacity:
Approx. 4.0 liters (4.2 US quarts) with filter change.
Recommended Oil Type:
API SG/SH/SJ, ACEA A2/A3, SAE 5W-40 or 10W-40 Synthetic Motorcycle Oil.
🔧 Transmission
Standard
Transmission Type:
5-speed manual gearbox with integral clutch.
Features
Clutch Type:
Hydraulically operated multi-plate wet clutch.
Final Drive:
Shaft drive
Fluid Specifications
Transmission Oil Type:
SAE 75W-90 GL-5 gear oil (BMW recommends specific grades, manual will detail).
Fluid Capacity
Transmission Oil Capacity:
Approximately 0.5 liters (0.53 US quarts).
📐 Dimensions
Exterior
Length:
Approx. 2430 mm (95.7 in)
Width:
Approx. 960 mm (37.8 in) at handlebars
Height:
Approx. 1580 mm (62.2 in) at windshield
Weights
Dry Weight:
Approx. 330 kg (728 lbs)
Gross Vehicle Weight Rating:
Approx. 540 kg (1190 lbs)
Wheelbase
Wheelbase:
Approx. 1629 mm (64.1 in)
Seat Height
Seat Height:
Approx. 790 mm (31.1 in)
🛡️ Safety Features
Ratings
ABS:
Integral ABS (often BMW's EVO ABS system).
Active Features
Braking System:
Dual front disc brakes, single rear disc brake. ABS system for enhanced control.
Lighting:
Halogen headlight, LED taillight, integrated turn signals.
Passive Features
Frame Design:
Sturdy aluminum frame providing rigidity and stability.
Wind Protection:
Large aerodynamic fairing and adjustable windshield for rider comfort and protection.
💡 Technology Features
Infotainment
Audio System:
Integrated audio system with AM/FM radio, CD player, and speakers (often with fairing-mounted controls).
Cruise Control:
Standard electronic cruise control for enhanced touring comfort.
Driver Assistance
ABS:
Integral ABS for improved braking safety, often with a linked brake feel.
Connectivity
Diagnostic Interface:
On-board diagnostics (OBD) capabilities with specific BMW connectors and diagnostic software, detailed in the manual.
Comfort Features
Heated Grips Seats:
Typically equipped with heated grips and heated seats for rider and passenger.
Electric Windshield:
Power-adjustable windshield for optimal rider comfort in varying conditions.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,000 miles) or annually, whichever comes first. Check manual for specifics.
Air Filter Replacement:
Inspect every 20,000 km (12,000 miles), replace as needed or at major service intervals. Consult manual for exact schedule.
Spark Plug Replacement:
Typically every 20,000 km (12,000 miles). Check manual for specific plug type and gap.
Brake Fluid Flush:
Every 2 years or as per manual recommendation.
Coolant Change:
Every 2-4 years or as specified in the manual.
Fluid Specifications
Brake Fluid Type:
DOT 4 (or DOT 4 LV for ABS systems, verify in manual).
Coolant Type:
BMWapproved ethylene glycol-based coolant, typically a blue or green mixture (check manual for exact BMW specification).
Known Issues
Fuel Pump Reliability:
Some earlier K-series models experienced occasional fuel pump issues. Regular checks and replacement if symptoms arise.
Rear Shock ABSorber:
As with many touring bikes, the rear shock absorber may wear over time, affecting ride quality. Manual will cover inspection and replacement procedures.
Electrical Connections:
Corrosion or loose connections in electrical components can lead to intermittent issues. Manual provides wiring diagrams for troubleshooting.
Clutch Actuator:
Potential for wear or leaks in the hydraulic clutch actuator. Manual details inspection and servicing.
📚 Vehicle History
Brand Heritage
Manufacturer:
Bayerische Motoren Werke AG (BMW)
Heritage:
BMW has a long and storied history in motorcycle manufacturing, known for its engineering prowess and innovative designs dating back to the early 20th century.
Model Evolution
K Series Introduction:
The K-series, introduced in the early 1980s, marked BMW's significant foray into multi-cylinder, liquid-cooled engines, breaking from their traditional boxer-twin designs.
K1200Lt Development:
The K1200LT was developed as BMW's flagship luxury touring motorcycle, building upon the K1100LT and K1200LT platforms with enhanced features, power, and comfort.
Production
Production Period:
The K1200LT model range was produced from 1997 to 2009, with significant updates throughout its lifecycle.
Manufacturing Location:
Germany
🏆 Awards & Recognition
Recognitions
Category:
Luxury Touring Motorcycle Segment
Recognition Type:
Consistently rated highly by motorcycle publications and owners for its comfort, performance, and touring capability during its production run.
Ratings
Overall Owner Satisfaction:
Generally high owner satisfaction due to its robust build and touring features, despite potential maintenance needs common to complex luxury vehicles.
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