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BMW K 1200 LT Service Manual – PDF DOWNLOAD
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Description
BMW K 1200 LT Service Manual
FILE DETAILS:
BMW K 1200 LT Service Manual
Language : English
Pages : 452
Downloadable : YES
Format : PDF
Size : 39.8 MB
DESCRIPTION:
BMW K 1200 LT Service Manual
INTRODUCTION:
This repair manual will help you to perform all the main maintenance and repair work correctly and efficiently. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and practical knowledge acquired at the BMW Training Centre. It is a contribution towards achieving even higher Service quality.
A new issue of this repair manual will be published if amendments or additions (supplements) are needed. All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification.
- The repair manual is structured in the logical sequence of the work to be performed: Removal, Disassembly, Repair, Assembly, Installation.
- The entire contents are divided into individual chapters, corresponding to the Construction Groups.
TABLE OF CONTENTS:
BMW K 1200 LT Service Manual
Repair Manual........................................................ 1 Introduction......................................................... 3 U sage........................................................... 4 Key to symbols................................................... 4 Contents..................................................... 4 Activities................................................... 4 Contents............................................................. 5 Maintenance schedule................................................. 7 Pre-delivery check................................................... 8 00 Maintenance and general instructions.............................. 9 Tightening torques............................................... 15 Table of operating fluids........................................ 27 Overview: K1200LT packing materials.............................. 29 Checking the shipping crate for damage........................... 30 Damage discovered in Germany................................. 30 Damage discovered in importer markets....................... 30 Unpacking the motorcycle......................................... 31 Installing the front wheel....................................... 32 General instructions............................................. 34 Pushing the motorcycle onto a workshop platform............. 34 Inspecting motorcycle for damage................................. 34 Checking that delivery is complete............................... 34 Installing remaining items on motorcycle........................ 35 Installing the front mudguard................................ 35 Installing the mirrors....................................... 35 Installing the footrests..................................... 36 Installing the rear left footrest plate.................. 36 Installing the rear right footrest and footrest pl....... 36 Installing the engine spoilers............................... 37 Installing the reverser control.............................. 37 Installing the skirts........................................ 37 Installing the top case...................................... 38 Additional instructions for moving the backrest.......... 38 Filling and charging the battery................................. 39 Checking brake fluid level....................................... 40 Front brake.................................................. 40 Rear brake................................................... 41 Checking clutch fluid level...................................... 42 Checking tyre pressures.......................................... 42 Checking tightness of rear wheel studs........................... 42 Installing the aerial............................................ 42 Installing the windscreen........................................ 43 Installing the windscreen cover.............................. 43 Checking and adjusting the motorcycle........................... 43 Checking the function of side stand contact switch........... 43 Adjusting the seat........................................... 43 Adjusting the top case....................................... 43 Checking headlight beam angle, adjusting if necess........... 44 Vertical adjustment...................................... 44 Lateral adjustment....................................... 44 Final inspection and function check.............................. 45 Final cleaning................................................... 45 Key to maintenance intervals..................................... 46 General instructions............................................. 47 Pushing the motorcycle onto a workshop platform............. 47 High idle speed.............................................. 47 Removing the aerial.......................................... 47 Reading the fault code memory with the MoDiTeC................... 48 (Inspections I, II, III and IV).............................. 48 Checking throttle cable play, adjusting if necess............... 48 (Inspections I and III)...................................... 48 Models without cruise control................................ 48 Models with cruise control................................... 48 Throttle-opener cable, throttle-closer cable............. 48 Cruise-control system cable.............................. 49 Turning the throttle twist grip relative to the th........... 49 Cruise control system does not switch off................ 49 Cruise control system cannot be set, or continuall....... 49 Changing engine oil, replacing oil filter element................ 50 (Inspections I, II, III and IV).............................. 50 Changing gearbox oil............................................. 51 Change the gearbox oil every two years at the late........... 51 (Inspection III)............................................. 51 Changing the oil in the rear wheel drive......................... 52 Change the oil in the rear wheel drive every two y........... 52 (Inspections I and III)...................................... 52 Brake pads/brake discs........................................... 53 Checking brake pads and discs for wear and replaci........... 53 (Inspections II and III)..................................... 53 Checking brake pads for wear................................. 53 Front brake pads......................................... 53 Rear brake pads.......................................... 53 Replacing brake pads......................................... 54 Front brake.............................................. 54 Rear brake............................................... 55 Checking the brake discs..................................... 56 Checking the front/rear brake fluid level........................ 56 (Inspections I, II and III).................................. 56 Checking the front brake fluid level......................... 56 Checking the fluid level with brake fluid reservoi....... 57 Checking the rear brake fluid level.......................... 58 (Inspections I, II and III).............................. 58 Checking operation of brake system and freedom fro........... 58 (Inspection III)......................................... 58 Changing brake fluid and bleeding brake system................... 59 Change the brake fluid once a year at the latest............. 59 (Inspection IV).............................................. 59 Front brake.................................................. 59 Forcing back the brake pistons........................... 59 Opening the brake fluid reservoir........................ 59 Bleeding the front brake pressure modulator.............. 60 Bleeding the left brake calliper......................... 60 Bleeding the front right brake calliper.................. 61 Rear brake................................................... 62 Bleeding the rear brake pressure modulator............... 62 Forcing back the brake pistons........................... 62 Bleeding the brake calliper.............................. 63 Checking clutch fluid level...................................... 63 (Inspections I, II and III).................................. 63 Changing the clutch fluid (every40,000km/24,00............... 64 Change the clutch fluid every 2 years at the lates........... 64 (Inspection III)............................................. 64 Replacing fuel filter (every40,000km/24,000 mile............... 66 (Inspection III)............................................. 66 Removing the fuel pump unit.................................. 66 Removing and installing fuel filter.......................... 67 Installing the fuel-pump unit................................ 67 Checking and topping up, if necessary, coolant le............... 68 (Inspections I and III)...................................... 68 Changing coolant................................................. 69 (Inspection IV).............................................. 69 Draining coolant............................................. 69 Filling coolant system....................................... 70 Battery.......................................................... 71 (Inspections III and IV)..................................... 71 Check battery acid level and add distilled water i........... 71 Checking battery acid level.................................. 71 Adding distilled water....................................... 71 Installing the battery....................................... 71 Replacing intake air filter element.............................. 72 (Inspection III)............................................. 72 Checking function of side stand contact switch................... 72 (Inspections I, II and III).................................. 72 Greasing the side stand.......................................... 73 (Inspections II, III and IV)................................. 73 Checking the centre stand, greasing if necessary................. 73 (Inspections II, III and IV)................................. 73 Checking the centre stand.................................... 73 Greasing the centre stand.................................... 73 Checking the steering damper..................................... 75 (Inspections II and III)..................................... 75 Checking tightness of rear wheel studs........................... 75 (Inspection I)............................................... 75 Checking rear wheel bearing play by tilting wheel................ 75 (Inspection III)............................................. 75 Checking swinging arm bearings, adjusting if neces............... 75 (Inspections I and III)...................................... 75 Cleaning the inductive sensor on the rear wheel (e............... 75 Clean the inductive sensor on the rear wheel every........... 75 (Inspection III)............................................. 75 Checking valve clearances, adjusting if necessary............... 76 (Inspection III)............................................. 76 Checking valve clearances.................................... 76 Adjusting valve clearances................................... 76 Replacing the chain tensioning rail lining and cha............... 78 (every 60,000 km/36,000 miles)............................... 78 Replacing spark plugs............................................ 79 (Inspection III)............................................. 79 Final inspection with road safety and functional c............... 79 (Inspections I, II, III and IV).............................. 79 11 Motor............................................................. 81 Cutaway drawing of engine, K 1200 LT............................. 91 Preparatory work with engine installed........................... 93 …for removal of combined oil/water pump...................... 93 …for removal of timing case cover, removal of timi........... 93 ...for removal of cylinder head.............................. 94 Removing/installing engine....................................... 94 Removing engine.............................................. 94 Group: frame............................................. 94 Groups: radiators, fuel tank and fuel lines.............. 94 Group: exhaust system.................................... 94 Groups: rear-wheel drive, wheels and tyres............... 95 Groups: frame and clutch................................. 95 Groups: engine electrical system and general vehic....... 95 Group: frame and gearbox................................. 95 Installing engine............................................ 96 Groups: frame and gearbox................................ 96 Group: clutch............................................ 96 Groups: engine electrical system and general vehic....... 96 Groups: frame, rear-wheel drive, wheels and tyres........ 96 Group: exhaust system.................................... 96 Groups: radiators, fuel tank and fuel lines.............. 96 Group: frame............................................. 96 Disassembling engine............................................. 97 Removing, disassembling/assembling water pump................ 97 Removing the oil/water pump.............................. 97 Disassembling the oil/water pump......................... 97 Removing slipring seal and shaft sealing ring............ 97 Removing the oil pressure relief valve................... 98 Installing the oil pressure relief valve................. 98 Oil-pressure switch, temperature sensor for water ....... 98 Installing the pump shaft with shaft sealing ring ....... 98 Installing water pump impeller........................... 98 Removing timing chain cover.................................. 99 Removing cylinder head cover............................. 99 Removing ignition pulse generator........................ 99 Removing timing chain cover.............................. 99 Removing/installing sealing ring in timing case co.......100 Removing the timing chain....................................101 Removing camshaft chain sprockets........................101 Removing chain tensioner rail............................101 Removing chain guide rail................................101 Renewing tensioning strap for chain tensioner rail.......102 Removing, disassembling and assembling cylinder h...........102 Removing camshafts.......................................102 Removing bucket-type tappets.............................102 Removing cylinder head...................................102 Removing valves..........................................102 Machining valve seat.....................................103 Installing valve and valve stem seal.....................104 Removing/installing crankshaft gear and rotor flan...........104 Removing crankshaft..........................................105 Removing big end bearings................................105 Removing main bearings (engine installed)................105 Removing main bearings (engine removed)..................105 Removing, disassembling and assembling piston with...........105 Removing piston with conrod..............................105 Disassembling piston.....................................105 Checking piston dimensions...............................106 Assembling pistons.......................................106 Checking cylinder dimensions.............................106 Checking that conrod bores are parallel..................106 Assembling pistons and conrods...........................107 Measure backlash at the countershaft.........................108 Removing intermediate flange.................................108 Removing driver..........................................108 Removing clutch housing..................................109 Removing intermediate flange.............................109 Disassembling/assembling intermediate flange.................110 Removing the driver bearing..............................110 Installing driver bearing................................110 Removing/installing shaft sealing ring for driver........111 Removing countershaft and layshaft with freewheel............111 Disassembling/assembling freewheel...........................112 Disassembling freewheel..................................112 Assembling freewheel.....................................113 Removing/installing needle bearing for layshaft an...........113 Removing bearing.........................................113 Removing shaft sealing ring..............................113 Installing shaft sealing ring............................113 Installing bearing.......................................113 Removing output shaft........................................114 Removing oil sump........................................114 Removing the oil mesh strainer and oil filter............114 Removing lower part of crankcase.........................114 Removing/installing oil level sight glass................114 Disassembling/reassembling output shaft......................115 Disassembling output shaft...............................115 Disassembling tensioning gear............................115 Assembling tensioning gear...............................116 Assembling damper........................................117 Assembling engine................................................117 Installing output shaft......................................117 Assembling the crankcase.................................117 Installing oil mesh strainer.............................118 Installing oil filter....................................118 Installing oil sump......................................118 Installing intermediate flange...............................119 Installing freewheel.....................................119 Installing countershaft..................................119 Installing intermediate flange...........................119 Installing output shaft sealing ring.....................119 Installing clutch housing................................120 Installing driver........................................120 Installing crankshaft........................................120 Measuring crankshaft bearing play............................121 Measuring radial play....................................121 Measuring endplay........................................121 Installing piston with conrod................................122 Installing big end bearing...................................122 Measuring big end bearing play...............................122 Checking dimensions of crankshaft............................123 Installing cylinder head.....................................124 Installing camshafts.........................................125 Installing timing chain......................................125 Installing timing case cover.................................127 Checking valve clearances....................................127 Adjusting valve clearances...................................127 Installing ignition pulse generator..........................128 Installing ignition pulse generator cover................128 Installing combined oil/water pump...........................129 Installing crankcase cover...................................129 Installing cylinder head cover...............................130 12 Engine electrics..................................................131 Removing and installing Hall-effect transmitters.................135 Preparatory work.............................................135 Removing cover from Hall-effect transmitter.................135 Removing magnetic gate.......................................135 Installing the magnetic gate.................................136 Installing the cover of the Hall-effect transmitte...........136 Replacing spark plugs/ignition leads.............................137 Removing and installing spark plugs..........................137 Removing and installing ignition leads.......................137 Removing and installing coil.....................................138 Motorcycles without shield housing...........................138 Motorcycles with shield housing..............................139 Timing the ignition..............................................139 Preparatory work.............................................139 Setting timing with Motronic.................................140 Setting timing without Motronic..............................140 Replacing three-phase generator..................................141 Removing and installing three-phase generator................141 Disassembling the three-phase generator.....................141 Removing and installing drive housing....................141 Removing and installing voltage regulator................142 Replacing starter motor..........................................142 Removing and installing starter motor........................142 Disassembling/assembling starter motor.......................143 Replacing carbon brushes.................................143 13 Fuel preparation and control......................................145 Removing and installing Motronic control unit....................149 Replacing intake air filter element..............................149 See Group00.................................................149 Replacing air temperature sensor.................................149 Removing and installing intake air silencer......................150 Removing and installing fuel injection rail.....................151 Removing and installing injectors............................151 Removing and installing pressure regulator.......................152 Removing and installing throttle valve rail......................152 Removing and installing throttle valve actuator..................154 Replacing and adjusting throttle valve potentiomet...............154 Removing and installing intake stubs.............................155 Replacing fuel hoses.............................................155 Removing and installing throttle cables..........................156 Preparatory work for all Bowden cables.......................156 Removing and installing throttle- opener and throt...........156 Removing and installing Bowden cable of cruise-con...........158 Checking fuel pressure...........................................159 Removing and installing control unit of cruise-con...............159 See Group 65.................................................159 Checking throttle cable play, adjusting if necess...............159 See Group 00.................................................159 16 Fuel tank and lines...............................................161 Removing and installing fuel tank................................165 Renewing fuel filter.............................................166 Removing the fuel pump unit..................................166 Removing/installing fuel filter..............................167 Removing/installing fuel pump................................167 Installing the fuel-pump unit................................167 Removing/installing immersion-tube sensor........................168 Calibrating the immersion-tube sensor........................168 Removing/installing roll-over valve..............................168 17 Radiator..........................................................169 Coolant circuit..................................................173 Removing and installing coolant hoses............................175 Connecting hose between left and right radiators.............175 Hoses between radiators and coolant stub pipes...............175 Hose between coolant stub pipes..............................175 Coolant hose to water pump...................................175 Removing breather hose.......................................175 Vapour outlet hose...........................................175 Changing coolant.................................................176 See Group00.................................................176 Checking cooling system for leaks................................176 Removing and installing radiator with fan........................176 Removing and installing left radiator........................176 Removing and installing right radiator.......................178 Removing and installing coolant stub pipe on engin...............179 Removing and installing thermostat...............................179 Troubleshooting..................................................180 18 Exhaust system....................................................183 Removing and installing exhaust heat shield......................187 Removing and installing exhaust system...........................187 Removing oxygen sensor.......................................188 21 Clutch............................................................189 Removing and installing clutch...................................193 Preparatory work.............................................193 Removing clutch..............................................193 Removing clutch housing......................................194 Installing clutch housing....................................195 Installing clutch............................................196 Changing the clutch fluid/bleeding the clutch syst...............197 Removing and installing clutch lines.............................198 Removing and installing vent line............................199 Removing and installing clutch pressure line................200 Removing and installing clutch slave cylinder....................201 Removing and installing clutch release rod.......................202 23 Gearbox...........................................................203 Gearbox – sectional drawing......................................207 Replacing the shaft sealing rings in the gearbox h...............209 Replacing input shaft sealing ring at input side.............209 Replacing output shaft sealing ring..........................209 Replacing shaft sealing ring for selector shaft o...........209 Replacing input shaft sealing ring at output side............210 Replacing shaft sealing ring for selector drum..............210 Replacing shaft sealing ring for selector shaft.............210 Removing and installing actuating unit for reverse...............211 Removing and installing actuating control for reve...........211 Removing and installing actuating unit for reverse...........211 Disassembling/assembling double switch for reverse...........212 Removing gearbox.................................................212 Disassembling gearbox............................................215 Preparatory work.............................................215 Disassembling reverser gear train............................216 Removing gearbox housing.........................................218 Removing selector drum.......................................219 Disassembling/assembling selector shaft......................219 Removing gearbox shafts......................................220 Replacing grooved ball bearing on intermediate sha...........220 Disassembling/assembling input shaft.........................221 Disassembling input shaft................................221 Assembling input shaft...................................222 Checking travel of spring segment on input shaft.........222 Disassembling/assembling output shaft........................223 Disassembling output shaft...............................223 Assembling output shaft..................................224 Checking endplay.............................................225 Checking/adjusting fully assembled length of gearb...........226 Checking/adjusting fully assembled length of inter.......226 Checking/adjusting fully assembled length of outpu.......227 Checking/adjusting fully assembled length of input.......228 Checking/adjusting fully assembled length of selec.......229 Shimming selector shaft..................................230 Assembling gearbox...............................................231 Installing gearbox shafts....................................231 Installing input, output and intermediate shafts.........231 Installing selector shaft................................231 Installing selector drum.................................232 Installing gearbox housing...................................233 Installing reverser..........................................234 Performing a functional check............................236 Installing cover of reverser.............................236 Install actuator unit for reverser.......................237 Completing assembly of gearbox...............................238 Installing gearbox...............................................239 Removing and installing gearshift lever and linkag...............242 Removing and installing gearshift lever..........................242 Aligning rubber mounts...........................................243 Aligning left-hand rubber mount..............................243 Aligning right-hand rubber mount.............................243 31 Front fork........................................................245 Removing and installing telescopic forks and fork ...............249 Removing telescopic fork.....................................249 Removing fork bridge.........................................251 Disassembling fork bridge....................................252 Removing and installing pot-type joints..................252 Removing angular-contact ball bearing with stud..........252 Removing stud............................................253 Installing stud..........................................253 Installing angular-contact ball bearing with stud........253 Installing fork bridge.......................................253 Installing telescopic fork...................................254 Assembly specification for telescopic fork...................256 Disassembling/assembling telescopic fork leg....................257 Disassembling telescopic fork leg............................257 Assembling telescopic fork leg...............................257 Measuring telescopic fork........................................258 Examining slider tube bridge and fork bridge.................258 Checking runout of fixed tube................................258 Checking runout of slider tube...............................258 Removing and installing slider tube bridge.......................259 Removing and installing ball joint...........................260 Removing and installing front suspension strut..................261 Removing front suspension strut..............................261 Installing suspension strut..................................262 Removing and installing steering damper......................263 Checking the steering damper.................................263 See Group 00.............................................263 Removing and installing leading link.............................264 Removing leading link........................................264 Removing left angular-contact ball bearing for lea...........265 Installing left angular-contact ball bearing for l...........265 Installing leading link......................................266 Measuring the leading link.......................................267 32 Steering..........................................................269 Removing and installing left grip tube...........................273 Removing and installing right grip tube..........................274 Removing and installing clutch lever fitting.....................275 Removing and installing brake lever fitting......................276 Removing and installing handlebar................................277 Installation instructions for adjusting handlebar............278 Handlebar: adjusting horizontally........................278 Handlebar: adjusting height..............................278 Removing and installing piston in brake-lever fitt...............279 Adjusting lever play for front brake/ clutch.................280 Front brake..............................................280 Clutch...................................................280 Removing and installing left and right handlebar l...............280 Removing and installing throttle cables..........................280 See Group 13.................................................280 33 Rear wheel drive..................................................281 Rear wheel drive – cutaway drawing...............................285 Removing, disassembling, reassembling and install...............287 Removing rear wheel drive....................................287 Replacing taper roller bearing in rear wheel drive...........288 Removing input bevel pinion..................................288 Disassembling input bevel pinion.............................290 Removing needle roller bearing for input bevel pin.......291 Installing needle roller bearing for input bevel p.......291 Assembling input bevel pinion................................291 Installing input bevel pinion................................292 Removing crown wheel.........................................294 Installing crown wheel.......................................295 Checking/adjusting backlash..................................296 Checking tooth contact pattern...............................297 Shimming housing cover.......................................298 Installing housing cover.....................................298 Installing rear drive shaft..................................298 Installing rear wheel drive..................................299 Removing, disassembling, reassembling and install...............300 Removing rear swinging arm...................................300 Removing and installing flexible gaiter......................301 Removing and installing threaded ring bearings...............301 Removing bearing from left/right threaded ring...........301 Installing bearing in left/right threaded ring...........301 Removing drive shaft.........................................302 Checking universal joint for wear........................302 Installing drive shaft.......................................302 Installing rear swinging arm.................................303 Removing and installing suspension strut.....................305 34 Brakes............................................................307 Front brake calliper.............................................311 Removing and installing front brake calliper.................311 Removing and installing filler adapter.......................312 Removing and installing front brake pistons..................313 Rear brake calliper..............................................313 Removing and installing rear brake calliper..................313 Removing and installing rear brake pistons...................314 Removing and installing front brake disc.........................315 Removing and installing rear brake disc..........................315 Removing and installing front ABS sensor.........................316 Removing front ABS sensor ring...................................316 Adjusting front ABS sensor.......................................317 Marking the ABS sensor ring..................................317 Checking/adjusting ABS sensor gap............................317 Checking ABS sensor gap..................................317 Adjusting ABS sensor gap.................................317 Removing and installing rear ABS sensor..........................318 Adjusting rear ABS sensor........................................318 Marking the ABS sensor ring..................................318 Checking/adjusting ABS sensor gap............................319 Checking ABS sensor gap..................................319 Adjusting ABS sensor gap.................................319 Removing and installing rear brake master cylinder...............319 Checking/adjusting play at piston rod............................320 Checking play at piston rod..................................320 Adjusting play at piston rod.................................320 Removing and installing ABS control unit........................321 Removing and installing ABS relay............................323 Removing and installing front brake lines/hoses..................325 Removing front brake lines/hoses.............................325 Preparatory work.........................................325 Brake lines under fuel tank..............................326 Brake line/hose to telescopic fork.......................326 Brake hose to handlebar..................................327 Installing front brake lines/hoses...........................327 Removing and installing rear brake lines/hoses...................328 Removing brake lines/hoses...................................328 Preparatory work.........................................328 Brake hose to brake calliper.............................328 Brake hose to brake master cylinder......................329 Brake fluid reservoir with return hose...................329 Brake line to brake calliper.............................329 Installing brake lines/hoses.................................331 Checking brake pads for wear/ replacing brake pads...............331 See Group 00.................................................331 Checking brake fluid level.......................................331 See Group 00.................................................331 Replacing brake fluid and bleeding brake system..................331 See Group 00.................................................331 36 Wheels and tyres..................................................333 Removing and installing front wheel..............................337 Removing and installing wheel bearings..........................338 Removing left/right wheel bearings...........................338 Installing right/left wheel bearing..........................339 Installing left wheel bearing............................339 Installing right wheel bearing...........................339 Removing/installing rear wheel...................................340 Removing rear wheel..........................................340 Installing rear wheel........................................340 Static balancing of front and rear wheels........................341 Static balancing of front wheel..............................341 Static balancing of rear wheel...............................341 Checking front/rear wheel rim for run-out........................342 Checking front wheel rim for run-out.........................342 Checking rear wheel rim for run-out..........................343 46 Frame.............................................................345 Overview of fairing sections, K 1200 LT..........................351 Removing and installing fairing side section.....................352 Removing and installing mirror...............................352 Removing and installing fin..................................352 Removing and installing front turn indicator................352 Removing and installing bottom of tank cover.................353 Removing and installing fairing skirt........................353 Removing skirt...............................................353 Removing and installing fairing side section.................354 Removing and installing tank cover...............................355 Removing flap of radio compartment...........................355 Removing and installing engine spoiler...........................356 Removing/installing components mounted on side sec...............357 Removing air outlet duct.....................................357 Removing kneepad.............................................357 Removing grille..............................................357 Removing badge...............................................357 Removing rubber stop for radio cover.........................357 Removing and installing battery cover............................358 Removing windscreen..............................................359 Removing windscreen cover....................................359 Removing windscreen..........................................359 Removing and installing windscreen adjuster..................360 Removing and installing instrument cover.........................361 Removing and installing upper section of fairing................362 Removing and installing left/right handlebar trim................363 Removing and installing fork bridge cover........................363 Removing/installing interior trim................................364 Removing and installing left/right wind deflectors...............364 Removing and installing front mudguard..........................365 Removing and installing front mudguard front sect...........365 Removing and installing front mudguard rear secti...........365 Removing and installing front footrests.........................366 Removing and installing front right footrest plate...............366 Removing and installing front left footrest plate................367 Removing gearshift lever.....................................367 Removing and installing left/right rear footrest p...............367 Removing and installing rear footrests..........................368 Disassembling rear footrest..................................368 Disassembling and assembling side stand..........................369 Removing and installing main (centre) stand.....................369 See Group 00, Lubricating main stand.........................369 Removing and installing intake air pipe..........................369 Removing and installing skirt bracket............................370 Removing and installing crash bar............................370 Removing and installing radiator holder..........................371 Removing and installing rear- mounted components.................371 Removing and installing number-plate carrier.................371 Removing and installing top case.............................372 Additional instructions for moving the backrest..........372 Disassembling top case.......................................373 Removing/installing interior light.......................373 Removing mirror and document stowage compartment........373 Removing lid of top case.................................373 Removing base of top case................................374 Removing and installing rear carrier cover...................374 Removing and installing case trimmer.........................375 Removing and installing side case............................376 Removing and installing side case lid........................377 Removing and installing rear moulding........................377 Removing and installing rear carrier section.................378 Removing rear mudguard.......................................378 Removing and installing front fairing bracket....................379 Removing reflectors..........................................380 Removing upper reflector.................................380 Removing lower reflector.................................380 Removing and installing retaining plates in front ...........380 Checking running gear............................................381 Measuring wheel track offset.................................381 Example..................................................382 Checking the leading link for deformation...................382 See Group 31.............................................382 Removing and installing frame....................................383 Removing and installing rear frame...........................384 Removing and installing cross-tube...........................386 Preparatory work.........................................386 Additional preparations for removing engine, gearb.......386 Removing and installing cross-tube.......................386 Removing and installing left/right engine cross-me...........387 Removing main frame..........................................388 Installing main frame........................................389 51 Equipment.........................................................391 Removing and installing ignition switch/steering l...............393 Removing and installing lock barrel..........................393 Removing the lock barrel.................................393 Removing lock barrel if ignition key has broken of.......393 Installing lock barrel...................................393 Disassembling/assembling fuel tank lock..........................394 Removing and installing flap for tank cap....................394 Removing and installing snap lock for tank cap fla...........394 Removing and installing fuel tank lock barrel................394 Removing and installing lock barrel of fuel tank c...............395 Removing and installing locking system for front s...............396 Removing locking system......................................396 Removing and installing Bowden release cable.................396 Removing and installing lock barrel of side case.................397 Removing and installing lock barrel of top case..................397 52 Seat..............................................................399 Removing and installing seat.....................................401 Removing and installing front seat with bridge...............401 Removing and installing rear seat............................401 Removing and installing rear seat backrest...................401 Disassembling/assembling front seat..............................402 Removing and installing front seat...........................402 Removing and installing gas-filled strut.....................402 61 General electrical equipment......................................403 Wiring harness...................................................407 View from right..............................................407 View from left...............................................408 Rear frame wiring harness....................................409 Top case wiring..............................................410 Tank cover with radio/cassette player........................411 Connectors beside ABS control unit...........................411 Connectors on fairing bracket................................412 Relay positions in electronics box...........................413 Connectors, electronics box..................................413 Handlebar wiring.............................................414 Replacing fuses..................................................415 Motorcycle fuses.............................................415 Fuses........................................................415 Fuse for radio/cassette player...............................415 Removing and installing electronics box..........................416 Disassembling left multi-function switch.........................417 Preparatory work.............................................417 Removing and installing radio control unit...................417 Removing and installing clutch switch........................417 Removing left multi-function switch..........................418 Disassembling right multi-function switch........................418 Removing and installing right multi-function switc...........418 Removing brake light switch..................................419 Removing and installing control unit for reverser................420 Removing and installing inductive sensor for speed...............421 Removing and installing water temperature sensor................421 Replacing side stand switch......................................422 Removing and installing side stand switch....................422 Check operation of side stand switch.........................422 Replacing and adjusting foot brake light switch..................423 Removing and installing brake light switch...................423 Adjusting brake light switch.................................423 Removing and installing ignition switch/steering l...............424 Removing and installing fanfare horn.............................424 Removing and installing switch for gear indicator................425 Removing and installing power socket.............................425 Socket on engine spoiler.....................................425 Socket in top case...........................................425 Removing and installing cable for oil pressure swi...............426 Removing cables..............................................426 Installing cables............................................426 Removing and installing battery..................................426 See Group 00, Battery........................................426 Removing and installing battery carrier.........................426 See Group34, Removing ABS control unit......................426 Removing and installing front and rear ABS sensors...............426 See Group 34.................................................426 62 Instruments.......................................................427 Wiring colours...................................................431 Removing and installing instrument panel.........................432 Replacing telltale/warning lights................................433 Telltale/warning lights......................................433 Disassembling instrument cluster.................................434 Removing speedometer, rev. counter, temperature ga...........434 Removing clock...............................................434 Removing and installing wiring harness..........................435 63 Lights............................................................437 Removing and installing headlight................................441 Renewing bulbs...................................................441 Bulb for low-beam headlight/ high-beam headlight.............441 Low (dipped) beam headlight..............................441 High (main) beam headlight...............................442 Bulb, parking light..........................................442 Front turn signal............................................442 Rear lights..................................................442 Checking headlight beam angle, adjusting if necess...............443 Vertical adjustment..........................................443 Lateral adjustment...........................................443 65 Radio and optional extras.........................................445 Removing and installing speakers.................................447 Front speakers...............................................447 Preparatory work.........................................447 Treble speaker...........................................447 Bass speaker.............................................447 Loudspeaker box..........................................447 Rear speakers................................................448 Removing and installing radio/ cassette player...................448 Preparatory work.............................................448 Removing radio control unit..................................449 Removing radio/cassette player and wiring harness...........449 Removing and installing radio remote control unit................450 Removing and installing front radio remote control...........450 See Group 61, Removing and installing radio contro.......450 Removing and installing rear radio remote control ...........450 Removing and installing aerial holder............................450 Removing and installing on-board computer........................451 Removing and installing temperature sensor on upp...............451 Removing and installing control unit of cruise-con...............452
BMW K 1200 LT SERVICE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
