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BMW K1200LT 1999 2000 2001 2002 2003 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: K1200LT Model Nickname: Touring Luxury Body Style: Full-Fairing Touring Motorcycle Generation Generation Code: K589 Codes Chassis Code: K589 👋 Introduction Market Position Segment: Premium Full-Dress Touring Motorcycle Target Audience: Long-distance touring riders, couples, riders seeking comfort and amenities. Competitive Analysis Key Competitors: Honda Gold Wing, Harley-Davidson Electra Glide, Yamaha Royal Star Venture. Key Features Features: Integrated audio system, electric reverse, generous luggage capacity, heated grips and seats, powerful engine. Design Philosophy: BMW's focus on engineering excellence, rider comfort, and touring capability. 📋 Manual Details Coverage Areas Applicable Model Years: 1999, 2000, 2001, 2002, 2003, 2004 Region Coverage: Global (may include US/EU variations) Page Count Estimated Pages: 700-1200 (typical for comprehensive service manuals) Manual Type Manual Type: Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed rebuild procedures, torque specifications, component tolerances for the K1200LT engine. Fuel System: Fuel injection system diagnostics, component testing, fuel pump, injectors, pressure regulator. Ignition System: Spark plugs, ignition coils, timing, electronic control unit (ECU) interface. Transmission: Clutch operation, gearbox disassembly and assembly, gearshift mechanism. Drivetrain: Shaft drive system, final drive unit, universal joints, lubrication. Braking System: ABS system (if equipped), brake fluid bleeding, caliper overhaul, disc inspection, pad replacement. Suspension: Front fork (Duolever) disassembly, fork oil changes, rear shock absorber, spring preload adjustment. Electrical System: Wiring diagrams, battery, alternator, starter motor, lighting, instrumentation, diagnostics. Chassis Bodywork: Frame inspection, fairing removal and installation, seat adjustment, luggage systems. Cooling System: Radiator, fan, coolant, thermostat, flushing procedures. Exhaust System: Catalytic converter, mufflers, lambda sensors. Procedures Included Routine Maintenance: Oil changes, filter replacement, chain/shaft lubrication, tire pressure checks, brake pad inspection. Troubleshooting: Diagnostic flowcharts for common issues, error codes, symptom-based troubleshooting. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement. Electrical Diagnostics: Testing circuits, component replacement, wiring harness repair. ABS System Service: Bleeding procedures, sensor testing, module diagnostics. Bodywork Repair: Fairing repair, mounting point checks, accessory installation. Technical Depth Diagnostic Tools: Information on specific BMW diagnostic tools (e.g., GT1, DIS) and their usage for this model. Torque Specifications: Comprehensive list of all critical torque values for fasteners. Schematics: Detailed electrical and vacuum schematics. Special Tools: Identification and usage of required BMW specialty tools. 📊 Manual Specifications File Format File Format: PDF Searchability: Searchable text content for easy navigation and information retrieval. Print Quality Print Quality: High-resolution images and clear text for easy reading and printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Inline-four cylinder, four-stroke 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: 10.2:1 Valve Train: DOHC, 4 valves per cylinder Performance Horsepower: 95 hp @ 7000 rpm (claimed) Torque: 77 lb-ft @ 5250 rpm (claimed) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Bosch Motronic MA 2.4 Fuel Type: Unleaded gasoline, minimum 91 octane (RON + MON)/2 Fuel Capacity: 25 liters (6.6 US gal) 🔧 Transmission Standard Transmission Type: Constant mesh 5-speed manual Optional Transmission Options: N/A (only manual offered) Features Clutch Type: Wet multi-plate, hydraulically operated Final Drive: Shaft drive 📐 Dimensions Exterior Length: 2400 mm (94.5 in) Width: 970 mm (38.2 in) Height: 1430 mm (56.3 in) (adjustable seat height) Wheelbase: 1625 mm (64.0 in) Weights Dry Weight: 318 kg (701 lbs) Wet Weight: 345 kg (761 lbs) (approximate, with fluids) Gross Vehicle Weight Rating: 540 kg (1190 lbs) 🛡️ Safety Features Ratings Safety Certifications: Meets relevant EU and US safety standards for motorcycles. Active Features ABS: BMW Integral ABS (optional, standard on later models within this range). Brakes Front: Dual 305mm discs, 4-piston calipers Brakes Rear: Single 284mm disc, 2-piston caliper Passive Features Lighting: Halogen headlight, LED taillight Wind Protection: Extensive aerodynamic fairing, adjustable windscreen 💡 Technology Features Infotainment Audio System: Integrated AM/FM radio with CD player (typically). Controls: Handlebar-mounted controls for audio and other functions. Driver Assistance ABS: Integral ABS system, which applies both front and rear brakes with a single lever pull. Reverse Gear: Electric reverse assist for maneuvering. Connectivity Diagnostics: On-board diagnostics accessed via specialized BMW tools. 🔧 Maintenance Service Intervals Oil Change Interval: Every 10,000 km (6,000 miles) or annually Major Service Interval: Every 20,000 km (12,000 miles) - includes valve check, spark plugs. Brake Fluid Change: Every 2 years Fluid Specifications Engine Oil Type: SAE 15W-50 Synthetic Motorcycle Oil (BMW recommends specific grades; consult manual for exact BMW spec like SAE 15W-50, API SG/JASO MA) Engine Oil Capacity: Approximately 4.5 liters (4.8 US qt) with filter change Transmission Oil Type: Hypoid gear oil, SAE 80W/90 API GL-5 (Final drive) Coolant Type: Ethylene glycol based coolant, mixed 50/50 with distilled water Brake Fluid Type: DOT 4 Hydraulic Fluid Known Issues Common Issues: Starter motor solenoid failure,...
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BMW K1200LT 1999 2000 2001 2002 2003 2004 Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
K1200LT
Model Nickname:
Touring Luxury
Body Style:
Full-Fairing Touring Motorcycle
Generation
Generation Code:
K589
Codes
Chassis Code:
K589
👋 Introduction
Market Position
Segment:
Premium Full-Dress Touring Motorcycle
Target Audience:
Long-distance touring riders, couples, riders seeking comfort and amenities.
Competitive Analysis
Key Competitors:
Honda Gold Wing, Harley-Davidson Electra Glide, Yamaha Royal Star Venture.
Key Features
Features:
Integrated audio system, electric reverse, generous luggage capacity, heated grips and seats, powerful engine.
Design Philosophy:
BMW's focus on engineering excellence, rider comfort, and touring capability.
📋 Manual Details
Coverage Areas
Applicable Model Years:
1999, 2000, 2001, 2002, 2003, 2004
Region Coverage:
Global (may include US/EU variations)
Page Count
Estimated Pages:
700-1200 (typical for comprehensive service manuals)
Manual Type
Manual Type:
Service Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed rebuild procedures, torque specifications, component tolerances for the K1200LT engine.
Fuel System:
Fuel injection system diagnostics, component testing, fuel pump, injectors, pressure regulator.
Ignition System:
Spark plugs, ignition coils, timing, electronic control unit (ECU) interface.
Transmission:
Clutch operation, gearbox disassembly and assembly, gearshift mechanism.
Drivetrain:
Shaft drive system, final drive unit, universal joints, lubrication.
Braking System:
ABS system (if equipped), brake fluid bleeding, caliper overhaul, disc inspection, pad replacement.
Suspension:
Front fork (Duolever) disassembly, fork oil changes, rear shock absorber, spring preload adjustment.
Electrical System:
Wiring diagrams, battery, alternator, starter motor, lighting, instrumentation, diagnostics.
Chassis Bodywork:
Frame inspection, fairing removal and installation, seat adjustment, luggage systems.
Cooling System:
Radiator, fan, coolant, thermostat, flushing procedures.
Exhaust System:
Catalytic converter, mufflers, lambda sensors.
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, chain/shaft lubrication, tire pressure checks, brake pad inspection.
Troubleshooting:
Diagnostic flowcharts for common issues, error codes, symptom-based troubleshooting.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement.
Electrical Diagnostics:
Testing circuits, component replacement, wiring harness repair.
ABS System Service:
Bleeding procedures, sensor testing, module diagnostics.
Bodywork Repair:
Fairing repair, mounting point checks, accessory installation.
Technical Depth
Diagnostic Tools:
Information on specific BMW diagnostic tools (e.g., GT1, DIS) and their usage for this model.
Torque Specifications:
Comprehensive list of all critical torque values for fasteners.
Schematics:
Detailed electrical and vacuum schematics.
Special Tools:
Identification and usage of required BMW specialty tools.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Searchable text content for easy navigation and information retrieval.
Print Quality
Print Quality:
High-resolution images and clear text for easy reading and printing.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-four cylinder, four-stroke
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:
10.2:1
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower:
95 hp @ 7000 rpm (claimed)
Torque:
77 lb-ft @ 5250 rpm (claimed)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - Bosch Motronic MA 2.4
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON + MON)/2
Fuel Capacity:
25 liters (6.6 US gal)
🔧 Transmission
Standard
Transmission Type:
Constant mesh 5-speed manual
Optional
Transmission Options:
N/A (only manual offered)
Features
Clutch Type:
Wet multi-plate, hydraulically operated
Final Drive:
Shaft drive
📐 Dimensions
Exterior
Length:
2400 mm (94.5 in)
Width:
970 mm (38.2 in)
Height:
1430 mm (56.3 in) (adjustable seat height)
Wheelbase:
1625 mm (64.0 in)
Weights
Dry Weight:
318 kg (701 lbs)
Wet Weight:
345 kg (761 lbs) (approximate, with fluids)
Gross Vehicle Weight Rating:
540 kg (1190 lbs)
🛡️ Safety Features
Ratings
Safety Certifications:
Meets relevant EU and US safety standards for motorcycles.
Active Features
ABS:
BMW Integral ABS (optional, standard on later models within this range).
Brakes Front:
Dual 305mm discs, 4-piston calipers
Brakes Rear:
Single 284mm disc, 2-piston caliper
Passive Features
Lighting:
Halogen headlight, LED taillight
Wind Protection:
Extensive aerodynamic fairing, adjustable windscreen
💡 Technology Features
Infotainment
Audio System:
Integrated AM/FM radio with CD player (typically).
Controls:
Handlebar-mounted controls for audio and other functions.
Driver Assistance
ABS:
Integral ABS system, which applies both front and rear brakes with a single lever pull.
Reverse Gear:
Electric reverse assist for maneuvering.
Connectivity
Diagnostics:
On-board diagnostics accessed via specialized BMW tools.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,000 miles) or annually
Major Service Interval:
Every 20,000 km (12,000 miles) - includes valve check, spark plugs.
Brake Fluid Change:
Every 2 years
Fluid Specifications
Engine Oil Type:
SAE 15W-50 Synthetic Motorcycle Oil (BMW recommends specific grades; consult manual for exact BMW spec like SAE 15W-50, API SG/JASO MA)
Engine Oil Capacity:
Approximately 4.5 liters (4.8 US qt) with filter change
Transmission Oil Type:
Hypoid gear oil, SAE 80W/90 API GL-5 (Final drive)
Coolant Type:
Ethylene glycol based coolant, mixed 50/50 with distilled water
Brake Fluid Type:
DOT 4 Hydraulic Fluid
Known Issues
Common Issues:
Starter motor solenoid failure, ABS modulator issues, fuel pump relay issues, occasional clutch slave cylinder leaks, suspension seal leaks.
Electrical Gremlins:
Can occur due to vibration and age; thorough inspection of wiring and connectors is key.
📚 Vehicle History
Brand Heritage
Heritage:
BMW Motorrad has a long history of engineering innovation and producing high-quality, durable motorcycles, particularly in the touring segment.
Model Evolution
Predecessor:
K1100LT
Successor:
K1200LT (facelifted versions), R1200LT (air-cooled boxer)
Key Updates In Range:
Incremental updates in electronics, ABS availability, and features across these model years.
Production
Production Period:
1997-2009 (for the K589 platform)
Manufacturing Location:
Berlin, Germany
🏆 Awards & Recognition
Recognitions
Awards:
While specific awards for individual model years are rare, the K1200LT platform was consistently praised for its touring comfort and features by motorcycle publications.
Ratings
Reviews:
Generally received positive reviews for its blend of performance, comfort, and amenities, establishing it as a top-tier touring machine.
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