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BMW K1200LT 1997-2004 Repair Service Manual

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🏷️ Basic Information Identification Make: BMW Model: K1200LT Model Code: K589 Generation Generation Designation: First Generation (K589) Codes Production Years Covered: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 👋 Introduction Market Position Vehicle Segment: Luxury Touring Motorcycle Target Audience: Motorcyclists seeking long-distance comfort, advanced features, and premium touring capabilities. Competitive Analysis Key Competitors: Honda Gold Wing, Harley-Davidson Electra Glide, Kawasaki Vulcan Voyager, Yamaha Royal Star Venture. Key Features Distinctive Attributes: Powerful flat-four engine, advanced Telelever and Paralever suspension, comprehensive fairing with integrated audio and climate control, electric windscreen, ABS, reverse gear (on some models). Manual Value Proposition: Provides enthusiasts and professional mechanics with the in-depth knowledge to maintain, diagnose, and repair the K1200LT effectively, ensuring longevity and optimal performance. 📋 Manual Details Coverage Areas Manual Type: Repair Service Manual Language: English Format: PDF Download Page Count Estimated Page Count: Over 800 Pages (typical for comprehensive service manuals of this era) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, inspection, and repair procedures for the K589 engine. Fuel System: Fuel injection system (EFI) components, fuel pump, injectors, fuel pressure regulation, and diagnosis. Ignition System: Ignition coils, spark plugs, ECU control, timing, and troubleshooting. Cooling System: Radiator, coolant, water pump, fan, hoses, and thermostat replacement and service. Exhaust System: Catalytic converter, mufflers, pipes, and emission control system components. Transmission And Drivetrain: Clutch operation, gearbox inspection and repair, driveshaft, and final drive servicing. Suspension System: Front telelever suspension, rear Paralever suspension, shock absorbers, fork seals, and linkage inspection. Braking System: ABS II (or later iterations depending on model year), brake calipers, master cylinders, brake lines, fluid bleeding, and pad/rotor replacement. Electrical System: Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting systems, and accessory power. Instrumentation And Controls: Dashboard, switches, levers, throttle, and all control cable servicing. Bodywork And Chassis: Fairing removal and installation, body panel repair, seat mechanisms, and frame inspection. Comfort Features: Heated grips and seat, power windscreen adjustment, cruise control system servicing. Diagnostics: On-board diagnostics (OBD) information, error codes, and troubleshooting procedures. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug inspection/replacement, fluid level checks, brake pad inspection. Troubleshooting Guides: Systematic diagnostic procedures for common and uncommon issues across all vehicle systems. Component Rebuilds: Detailed instructions for overhauling major components like the engine, transmission, and suspension. Electrical Troubleshooting: Step-by-step diagnostics using wiring diagrams to pinpoint electrical faults. Suspension Adjustment: Instructions for adjusting or rebuilding front and rear suspension units. Brake System Maintenance: Bleeding procedures for ABS systems, caliper rebuilds, and rotor replacement. Bodywork Repair: Guidance on removing and reinstalling fairings, minor body panel repairs, and trim piece replacement. Technical Depth Diagnostic Level: Advanced diagnostics, including interpreting sensor data and troubleshooting electronic control modules (ECMs). Repair Scope: Comprehensive repair procedures, from minor adjustments to major component overhauls and engine rebuilds. Specifications Detail: Precise torque specifications, tolerances, fluid capacities, and diagnostic parameters. Diagrams And Illustrations: Detailed exploded views, wiring diagrams, and step-by-step procedural illustrations. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Printability: Printable pages for workshop use. File Quality: High-resolution scans ensuring clarity of text and images. Print Quality Digital Resolution: High DPI (dots per inch) for clear visual reproduction. Binding Type Digital Format Type: Electronic Download (PDF) Paper Type Digital Usage: Accessible on computers, tablets, and smartphones. ⚙️ Engine Specifications Primary Engine Engine Type: Inline Four-Cylinder, Four-Stroke Engine Code: K589 (shared across the LT and GT models of this era) Displacement: 1171 cc (71.7 cu in) Bore X Stroke: 78.8 mm x 75 mm (3.10 in x 2.95 in) Compression Ratio: 10.5:1 Valve Train: DOHC (Double Overhead Camshaft), 4 valves per cylinder Performance Horsepower: 100 hp (75 kW) @ 6750 rpm (approximate, may vary slightly by year) Torque: 115 Nm (85 lb-ft) @ 5250 rpm (approximate, may vary slightly by year) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Bosch Motronic MA 2.4 (or similar) Fuel Type: Unleaded gasoline, minimum 95 RON (91 AKI) Fuel Tank Capacity: 21 Liters (5.5 US gal) Lubrication Oil Type: BMW Motorrad Approved Synthetic Motorcycle Oil, SAE 5W-40 or 10W-40 (refer to manual for precise BMW specification) Oil Capacity: Approx. 4.5 Liters (4.8 US qt) with filter change 🔧 Transmission Standard Transmission Type: 5-Speed Manual Clutch Type: Hydraulically operated, multi-plate wet clutch Features Final Drive: Shaft Drive Gear Ratios: Specific ratios will be detailed within the manual. 📐 Dimensions Exterior Length: Approx. 2,420 mm (95.3 in) Width: Approx. 980 mm (38.6 in) at mirrors Height: Approx. 1,430 mm (56.3 in) with windscreen at normal setting Weights Dry Weight: Approx. 296 kg (653 lbs) Gross Vehicle Weight Rating: Approx. 505 kg (1113 lbs) Payload Capacity: Approx. 209 kg (460 lbs) Wheelbase Wheelbase: Approx. 1,627 mm (64.1 in) Tires Front Tire Size: 120/70 ZR17 Rear Tire Size: 170/80 ZR15 🛡️ Safety...
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Sku: 508141
Collecties: ALL BMW

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BMW K1200LT 1997-2004 Repair Service Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
K1200LT
Model Code:
K589
Generation
Generation Designation:
First Generation (K589)
Codes
Production Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
👋 Introduction
Market Position
Vehicle Segment:
Luxury Touring Motorcycle
Target Audience:
Motorcyclists seeking long-distance comfort, advanced features, and premium touring capabilities.
Competitive Analysis
Key Competitors:
Honda Gold Wing, Harley-Davidson Electra Glide, Kawasaki Vulcan Voyager, Yamaha Royal Star Venture.
Key Features
Distinctive Attributes:
Powerful flat-four engine, advanced Telelever and Paralever suspension, comprehensive fairing with integrated audio and climate control, electric windscreen, ABS, reverse gear (on some models).
Manual Value Proposition:
Provides enthusiasts and professional mechanics with the in-depth knowledge to maintain, diagnose, and repair the K1200LT effectively, ensuring longevity and optimal performance.
📋 Manual Details
Coverage Areas
Manual Type:
Repair Service Manual
Language:
English
Format:
PDF Download
Page Count
Estimated Page Count:
Over 800 Pages (typical for comprehensive service manuals of this era)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine disassembly, assembly, inspection, and repair procedures for the K589 engine.
Fuel System:
Fuel injection system (EFI) components, fuel pump, injectors, fuel pressure regulation, and diagnosis.
Ignition System:
Ignition coils, spark plugs, ECU control, timing, and troubleshooting.
Cooling System:
Radiator, coolant, water pump, fan, hoses, and thermostat replacement and service.
Exhaust System:
Catalytic converter, mufflers, pipes, and emission control system components.
Transmission And Drivetrain:
Clutch operation, gearbox inspection and repair, driveshaft, and final drive servicing.
Suspension System:
Front telelever suspension, rear Paralever suspension, shock absorbers, fork seals, and linkage inspection.
Braking System:
ABS II (or later iterations depending on model year), brake calipers, master cylinders, brake lines, fluid bleeding, and pad/rotor replacement.
Electrical System:
Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting systems, and accessory power.
Instrumentation And Controls:
Dashboard, switches, levers, throttle, and all control cable servicing.
Bodywork And Chassis:
Fairing removal and installation, body panel repair, seat mechanisms, and frame inspection.
Comfort Features:
Heated grips and seat, power windscreen adjustment, cruise control system servicing.
Diagnostics:
On-board diagnostics (OBD) information, error codes, and troubleshooting procedures.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug inspection/replacement, fluid level checks, brake pad inspection.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon issues across all vehicle systems.
Component Rebuilds:
Detailed instructions for overhauling major components like the engine, transmission, and suspension.
Electrical Troubleshooting:
Step-by-step diagnostics using wiring diagrams to pinpoint electrical faults.
Suspension Adjustment:
Instructions for adjusting or rebuilding front and rear suspension units.
Brake System Maintenance:
Bleeding procedures for ABS systems, caliper rebuilds, and rotor replacement.
Bodywork Repair:
Guidance on removing and reinstalling fairings, minor body panel repairs, and trim piece replacement.
Technical Depth
Diagnostic Level:
Advanced diagnostics, including interpreting sensor data and troubleshooting electronic control modules (ECMs).
Repair Scope:
Comprehensive repair procedures, from minor adjustments to major component overhauls and engine rebuilds.
Specifications Detail:
Precise torque specifications, tolerances, fluid capacities, and diagnostic parameters.
Diagrams And Illustrations:
Detailed exploded views, wiring diagrams, and step-by-step procedural illustrations.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval.
Printability:
Printable pages for workshop use.
File Quality:
High-resolution scans ensuring clarity of text and images.
Print Quality
Digital Resolution:
High DPI (dots per inch) for clear visual reproduction.
Binding Type
Digital Format Type:
Electronic Download (PDF)
Paper Type
Digital Usage:
Accessible on computers, tablets, and smartphones.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline Four-Cylinder, Four-Stroke
Engine Code:
K589 (shared across the LT and GT models of this era)
Displacement:
1171 cc (71.7 cu in)
Bore X Stroke:
78.8 mm x 75 mm (3.10 in x 2.95 in)
Compression Ratio:
10.5:1
Valve Train:
DOHC (Double Overhead Camshaft), 4 valves per cylinder
Performance
Horsepower:
100 hp (75 kW) @ 6750 rpm (approximate, may vary slightly by year)
Torque:
115 Nm (85 lb-ft) @ 5250 rpm (approximate, may vary slightly by year)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Bosch Motronic MA 2.4 (or similar)
Fuel Type:
Unleaded gasoline, minimum 95 RON (91 AKI)
Fuel Tank Capacity:
21 Liters (5.5 US gal)
Lubrication
Oil Type:
BMW Motorrad Approved Synthetic Motorcycle Oil, SAE 5W-40 or 10W-40 (refer to manual for precise BMW specification)
Oil Capacity:
Approx. 4.5 Liters (4.8 US qt) with filter change
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual
Clutch Type:
Hydraulically operated, multi-plate wet clutch
Features
Final Drive:
Shaft Drive
Gear Ratios:
Specific ratios will be detailed within the manual.
📐 Dimensions
Exterior
Length:
Approx. 2,420 mm (95.3 in)
Width:
Approx. 980 mm (38.6 in) at mirrors
Height:
Approx. 1,430 mm (56.3 in) with windscreen at normal setting
Weights
Dry Weight:
Approx. 296 kg (653 lbs)
Gross Vehicle Weight Rating:
Approx. 505 kg (1113 lbs)
Payload Capacity:
Approx. 209 kg (460 lbs)
Wheelbase
Wheelbase:
Approx. 1,627 mm (64.1 in)
Tires
Front Tire Size:
120/70 ZR17
Rear Tire Size:
170/80 ZR15
🛡️ Safety Features
Ratings
ABS System:
BMW Integral ABS (Generation II or similar depending on exact model year) - full integral, and optional anti-lock functionality on front and rear brakes independently.
Active Features
Braking System Type:
Dual front disc brakes with 4-piston calipers, Single rear disc brake with 2-piston caliper.
Lighting:
Halogen headlights, integrated turn signals, comprehensive rear lighting.
Passive Features
Frame Construction:
Aluminum composite bridge frame.
Rider Aids:
ABS, potentially traction control on later models within this range (TCS was introduced for the K1200GT later, it's less common but possible on late LT). Manual will cover its diagnosis if present.
💡 Technology Features
Infotainment
Audio System:
Integrated radio (AM/FM) and cassette player or CD player (depending on year and options), often with handlebar-mounted controls. Compatibility with aftermarket audio upgrades is a common modification.
Speaker Configuration:
Fairing-mounted speakers.
Driver Assistance
Cruise Control:
Standard electronic cruise control for enhanced long-distance comfort.
Windscreen Adjustment:
Electrically operated windscreen for adjustable rider wind protection.
Connectivity
Diagnostics Port:
On-board diagnostic connector for accessing fault codes and system data. The manual details these procedures.
Comfort Features
Heated Grips And Seat:
Adjustable heated grips for rider and passenger, and a multi-level heated seat for rider and passenger.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 10,000 km (6,200 miles) or annually, whichever comes first.
Air Filter Inspection:
Every 10,000 km (6,200 miles), replace as needed.
Spark Plug Replacement:
Every 20,000 km (12,400 miles) or as specified for iridium plugs.
Brake Fluid Change:
Every 2 years, regardless of mileage.
Final Drive Oil Change:
Every 20,000 km (12,400 miles).
Valve Clearance Check:
Every 40,000 km (24,800 miles).
Fluid Specifications
Engine Oil Specification:
BMW Motorrad Approved Synthetic SAE 5W-40 or 10W-40 (Refer to manual for specific BMW Longlife-XX rating, e.g., Longlife-04 or earlier equivalents).
Brake Fluid Type:
DOT 4 (for ABS and non-ABS systems).
Final Drive Oil:
API GL-5, SAE 75W-90 synthetic hypoid gear oil.
Coolant Type:
BMW recommended coolant/antifreeze mixture (e.g., ethylene glycol-based with corrosion inhibitors).
Known Issues
Common Wear Items:
Clutch wear, fuel pump relay failures, starter motor brushes, rear wheel bearings, front fork seals, electrical connectors susceptible to corrosion.
Electronic Issues:
ABS sensor failures, CAN bus communication issues (on later models), dashboard display glitches.
Engine Specific Concerns:
Occasional stator failures, ignition coil pack issues.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Germany
Bmw Motorcycle Legacy:
BMW has a long history of producing technically advanced and durable motorcycles, particularly known for their boxer engines and later, their inline-four and inline-six cylinder configurations.
Model Evolution
K Series Introduction:
The K series, introduced in the early 1980s, marked BMW's foray into inline-four engines, emphasizing smooth power delivery and shaft drive, setting a precedent for luxury touring bikes.
K1200Lt Positioning:
The K1200LT (K589) was the flagship luxury tourer for BMW in its time, building upon the K1100LT and K100LT, and was designed for maximum rider and passenger comfort on long journeys.
Production
Manufacturing Plant:
Berlin, Germany (Spandau)
Production Period For This Manual:
1997 - 2004 (covering the entirety of the K589 generation).
🏆 Awards & Recognition
Recognitions
Market Reputation:
Consistently praised for its comfort, stability, and long-distance touring capabilities, earning a reputation as a premier touring machine.
Ratings
Performance Reviews:
Frequently received high marks from motorcycle journalists for its smooth engine, sophisticated suspension, and comprehensive touring amenities.
Certifications
Emissions Standards:
Designed to meet the emissions standards of its respective production years and target markets.
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