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Bmw K1200LT Service Workshop Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: K1200LT Model Type: Touring Motorcycle Generation Generation Designation: First Generation (K589) Production Start Year: 1999 Production End Year: 2009 Codes Chassis Code: K589 👋 Introduction Market Position Category: Luxury Touring Motorcycle Target Audience: Long-distance touring riders seeking comfort, features, and performance. Competitive Analysis Competitors: Honda Gold Wing, Harley-Davidson Electra Glide, Yamaha Royal Star Venture. Key Differentiators: BMW's signature Boxer engine feel (though this is an inline-4), advanced engineering, and handling characteristics. Key Features Feature 1: Spacious and comfortable rider and passenger accommodations. Feature 2: Integrated luggage system for ample storage. Feature 3: Advanced electronic features like cruise control and electric windscreen. Feature 4: Powerful inline-four engine providing strong torque and smooth operation. 📋 Manual Details Coverage Areas Engine Service: Complete overhaul, diagnosis, and repair of the K1200LT engine. Transmission Service: Clutch, gearbox, final drive inspection, maintenance, and repair procedures. Electrical System: Wiring diagrams, component testing, diagnosis, and repair of all electrical systems. Chassis And Suspension: Fork, rear shock, swingarm, wheel bearing, and steering head bearing service. Braking System: ABS (Integral ABS II), caliper, disc, and hydraulic system maintenance and repair. Fuel System: Fuel injection system (BMS-K), fuel pump, injectors, and EVAP system. Cooling System: Radiator, fan, water pump, thermostat, and coolant service. Exhaust System: Catalytic converter, muffler, and exhaust pipe service and inspection. Bodywork And Fairings: Disassembly, reassembly, and repair of all body panels and fairings. Diagnostics And Troubleshooting: Fault code diagnosis, common problems, and step-by-step troubleshooting guides. Maintenance Schedule: Detailed service intervals for all routine maintenance tasks. Page Count Estimated Pages: 700+ Manual Type Type: Factory Service Manual / Workshop Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: 1171cc DOHC Inline-4 Cylinder Engine Engine Management: Bosch Motronic BMS-K Engine Management System Fuel Delivery: Fuel Injection, ECU controlled Ignition System: Electronic Ignition, Dual Spark Plugs per Cylinder Transmission: 6-Speed Constant Mesh Gearbox Final Drive: Shaft Drive with Paralever System Suspension Front: Duolever Front Suspension System Suspension Rear: Monolever Rear Suspension System Brakes Front: Dual Disc Brakes with Integral ABS II Brakes Rear: Single Disc Brake with Integral ABS II Electrical System Component: Lighting, Indicators, Horn, Battery, Charging System, Starter Motor Instrumentation: Dashboard Displays, Warning Lights, Speedometer, Tachometer Comfort Features: Electric Windscreen, Heated Grips, Heated Seats, Cruise Control, Reverse Gear Audio System: BMW Audio System (if equipped) Procedures Included Engine Overhaul: Complete top-end and bottom-end engine rebuild procedures. Valve Adjustment: Correct procedure for checking and adjusting valve clearances. Clutch Replacement: Step-by-step guide for clutch disc and pressure plate replacement. Transmission Rebuild: Detailed instructions for gearbox disassembly and reassembly. Suspension Fork Service: Fork seal replacement, oil change, and internal component service. Rear Shock Overhaul: Service procedures for the rear shock absorber. Brake System Bleeding: Correct procedure for bleeding the Integral ABS II braking system. Fuel Injector Cleaning: Procedure for cleaning and testing fuel injectors. Wiring Harness Repair: Diagnostic and repair procedures for electrical wiring issues. Body Panel Removal Installation: Detailed guide for fairing and body panel removal and reinstallation. Cruise Control Setup Diagnosis: Installation and troubleshooting of the cruise control system. Reverse Gear Operation Maintenance: Information on the electric reverse gear system. Diagnostic Troubleshooting Charts: Systematic approach to diagnosing common and complex issues. Technical Depth Depth: Comprehensive from basic maintenance to full engine and transmission rebuilds. Diagnostic Level: Advanced diagnostics including ECU fault code interpretation and system testing. Repair Scope: Covers all mechanical, electrical, and electronic components. 📊 Manual Specifications File Format Format Details: Searchable PDF document, allowing for quick keyword access to information. Print Quality Image Resolution: High-resolution images and diagrams for clarity. Diagram Detail: Detailed part diagrams with exploded views. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, four-stroke Displacement: 1171 cc Bore X Stroke: 79 mm x 59 mm Compression Ratio: 11.5:1 Valve Train: DOHC, 4 valves per cylinder Cooling System: Liquid-cooled Performance Horsepower: 100 hp @ 7500 rpm (approx.) Torque: 115 Nm (85 lb-ft) @ 6000 rpm (approx.) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Bosch Motronic BMS-K Fuel Type: Unleaded Premium (95 RON / 91 AKI) Fuel Tank Capacity: 24 Liters (6.3 US gal) 🔧 Transmission Standard Transmission Type: 6-speed, claw-shifted, constant mesh gearbox Clutch Type: Single dry plate, mechanically operated Final Drive: Shaft drive Features Reverse Gear: Electric reverse gear 📐 Dimensions Exterior Length: 2420 mm (95.3 in) Width Over Fairings: 990 mm (39.0 in) Height Over Windscreen: 1630 mm (64.2 in) Weights Dry Weight: 339 kg (747 lbs) Gross Vehicle Weight Rating: 570 kg (1257 lbs) 🛡️ Safety Features Ratings ABS: Integral ABS II (Anti-lock Braking System) Active Features Lighting: Halogen Headlight, LED Taillight, Turn Signals Braking System Type: Linked Integral ABS II Passive Features Fairing Design: Full aerodynamic fairing for rider protection from...
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Bmw K1200LT Service Workshop Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
K1200LT
Model Type:
Touring Motorcycle
Generation
Generation Designation:
First Generation (K589)
Production Start Year:
1999
Production End Year:
2009
Codes
Chassis Code:
K589
👋 Introduction
Market Position
Category:
Luxury Touring Motorcycle
Target Audience:
Long-distance touring riders seeking comfort, features, and performance.
Competitive Analysis
Competitors:
Honda Gold Wing, Harley-Davidson Electra Glide, Yamaha Royal Star Venture.
Key Differentiators:
BMW's signature Boxer engine feel (though this is an inline-4), advanced engineering, and handling characteristics.
Key Features
Feature 1:
Spacious and comfortable rider and passenger accommodations.
Feature 2:
Integrated luggage system for ample storage.
Feature 3:
Advanced electronic features like cruise control and electric windscreen.
Feature 4:
Powerful inline-four engine providing strong torque and smooth operation.
📋 Manual Details
Coverage Areas
Engine Service:
Complete overhaul, diagnosis, and repair of the K1200LT engine.
Transmission Service:
Clutch, gearbox, final drive inspection, maintenance, and repair procedures.
Electrical System:
Wiring diagrams, component testing, diagnosis, and repair of all electrical systems.
Chassis And Suspension:
Fork, rear shock, swingarm, wheel bearing, and steering head bearing service.
Braking System:
ABS (Integral ABS II), caliper, disc, and hydraulic system maintenance and repair.
Fuel System:
Fuel injection system (BMS-K), fuel pump, injectors, and EVAP system.
Cooling System:
Radiator, fan, water pump, thermostat, and coolant service.
Exhaust System:
Catalytic converter, muffler, and exhaust pipe service and inspection.
Bodywork And Fairings:
Disassembly, reassembly, and repair of all body panels and fairings.
Diagnostics And Troubleshooting:
Fault code diagnosis, common problems, and step-by-step troubleshooting guides.
Maintenance Schedule:
Detailed service intervals for all routine maintenance tasks.
Page Count
Estimated Pages:
700+
Manual Type
Type:
Factory Service Manual / Workshop Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
1171cc DOHC Inline-4 Cylinder Engine
Engine Management:
Bosch Motronic BMS-K Engine Management System
Fuel Delivery:
Fuel Injection, ECU controlled
Ignition System:
Electronic Ignition, Dual Spark Plugs per Cylinder
Transmission:
6-Speed Constant Mesh Gearbox
Final Drive:
Shaft Drive with Paralever System
Suspension Front:
Duolever Front Suspension System
Suspension Rear:
Monolever Rear Suspension System
Brakes Front:
Dual Disc Brakes with Integral ABS II
Brakes Rear:
Single Disc Brake with Integral ABS II
Electrical System Component:
Lighting, Indicators, Horn, Battery, Charging System, Starter Motor
Instrumentation:
Dashboard Displays, Warning Lights, Speedometer, Tachometer
Comfort Features:
Electric Windscreen, Heated Grips, Heated Seats, Cruise Control, Reverse Gear
Audio System:
BMW Audio System (if equipped)
Procedures Included
Engine Overhaul:
Complete top-end and bottom-end engine rebuild procedures.
Valve Adjustment:
Correct procedure for checking and adjusting valve clearances.
Clutch Replacement:
Step-by-step guide for clutch disc and pressure plate replacement.
Transmission Rebuild:
Detailed instructions for gearbox disassembly and reassembly.
Suspension Fork Service:
Fork seal replacement, oil change, and internal component service.
Rear Shock Overhaul:
Service procedures for the rear shock absorber.
Brake System Bleeding:
Correct procedure for bleeding the Integral ABS II braking system.
Fuel Injector Cleaning:
Procedure for cleaning and testing fuel injectors.
Wiring Harness Repair:
Diagnostic and repair procedures for electrical wiring issues.
Body Panel Removal Installation:
Detailed guide for fairing and body panel removal and reinstallation.
Cruise Control Setup Diagnosis:
Installation and troubleshooting of the cruise control system.
Reverse Gear Operation Maintenance:
Information on the electric reverse gear system.
Diagnostic Troubleshooting Charts:
Systematic approach to diagnosing common and complex issues.
Technical Depth
Depth:
Comprehensive from basic maintenance to full engine and transmission rebuilds.
Diagnostic Level:
Advanced diagnostics including ECU fault code interpretation and system testing.
Repair Scope:
Covers all mechanical, electrical, and electronic components.
📊 Manual Specifications
File Format
Format Details:
Searchable PDF document, allowing for quick keyword access to information.
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity.
Diagram Detail:
Detailed part diagrams with exploded views.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, four-stroke
Displacement:
1171 cc
Bore X Stroke:
79 mm x 59 mm
Compression Ratio:
11.5:1
Valve Train:
DOHC, 4 valves per cylinder
Cooling System:
Liquid-cooled
Performance
Horsepower:
100 hp @ 7500 rpm (approx.)
Torque:
115 Nm (85 lb-ft) @ 6000 rpm (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Bosch Motronic BMS-K
Fuel Type:
Unleaded Premium (95 RON / 91 AKI)
Fuel Tank Capacity:
24 Liters (6.3 US gal)
🔧 Transmission
Standard
Transmission Type:
6-speed, claw-shifted, constant mesh gearbox
Clutch Type:
Single dry plate, mechanically operated
Final Drive:
Shaft drive
Features
Reverse Gear:
Electric reverse gear
📐 Dimensions
Exterior
Length:
2420 mm (95.3 in)
Width Over Fairings:
990 mm (39.0 in)
Height Over Windscreen:
1630 mm (64.2 in)
Weights
Dry Weight:
339 kg (747 lbs)
Gross Vehicle Weight Rating:
570 kg (1257 lbs)
🛡️ Safety Features
Ratings
ABS:
Integral ABS II (Anti-lock Braking System)
Active Features
Lighting:
Halogen Headlight, LED Taillight, Turn Signals
Braking System Type:
Linked Integral ABS II
Passive Features
Fairing Design:
Full aerodynamic fairing for rider protection from elements.
Passenger Features:
Comfortable passenger seat with backrest and armrests.
💡 Technology Features
Infotainment
Audio System Features:
AM/FM Radio, CD Player (early models), auxiliary input, weather band (often integrated with CB radio option).
Driver Assistance
Cruise Control:
Electronically controlled cruise control system.
Braking ABS:
Integral ABS II providing linked braking and anti-lock functionality.
Connectivity
Diagnostic Port:
BMW proprietary diagnostic connector for electronic diagnostics.
Comfort Features Tech
Electric Windscreen:
Electrically adjustable windscreen for variable wind protection.
Heated Elements:
Heated grips and heated rider/passenger seats for cold-weather comfort.
Power System:
12V Electrical System with 700W Alternator.
🔧 Maintenance
Service Intervals
Oil Change:
Every 10,000 km (6,000 miles) or annually.
Valve Check:
Every 20,000 km (12,000 miles).
Spark Plug Replacement:
Every 40,000 km (24,000 miles).
Brake Fluid Change:
Every 2 years.
Fluid Specifications
Engine Oil Type:
SAE 5W-40 Synthetic Motorcycle Oil, API SG/SH or JASO MA compliant.
Engine Oil Capacity:
Approx. 4.0 Liters (4.2 US quarts) with filter.
Transmission Oil Type:
SAE 75W-90 Synthetic Gear Oil (API GL-5 or GL-4/GL-5).
Transmission Oil Capacity:
Approx. 1.0 Liter (1.1 US quarts).
Final Drive Oil Type:
SAE 75W-90 Synthetic Gear Oil (API GL-5 or GL-4/GL-5).
Final Drive Oil Capacity:
Approx. 220 ml (7.4 US fl oz).
Coolant Type:
BMW approved mixture of Ethylene Glycol and distilled water (50/50).
Brake Fluid Type:
DOT 4 Brake Fluid.
Known Issues
Issue 1:
Sticking starter motor solenoid (requires solenoid replacement or cleaning).
Issue 2:
Water pump seal leaks (common on higher mileage units).
Issue 3:
ABS modulator issues (rare, but can be costly to repair).
Issue 4:
Heated grip elements can fail over time.
📚 Vehicle History
Brand Heritage
Heritage Focus:
BMW Motorrad's legacy of engineering excellence and rider-focused design.
Model Evolution
Predecessor:
K1100LT
Key Updates Over Production:
Introduction of Integral ABS II, enhanced electrical system, revised ECU mapping, improved seating comfort.
Production
Manufacturing Location:
Berlin, Germany
🏆 Awards & Recognition
Recognitions
Recognition Type:
Consistently rated as a top touring motorcycle by enthusiasts and publications for its comfort and long-distance capability.
Ratings
Owner Satisfaction:
Generally high owner satisfaction due to its touring prowess and build quality.
Certifications
Certification Type:
Meets all relevant European and North American emissions and safety standards for motorcycles of its era.
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