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BMW AG Motorcycle Division

After Sales

K 1200 LT

Repair Manual

Summary of content (452 pages)

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Repair Manual K 1200 LT BMW AG Motorcycle Division After Sales
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Published by: © BMW AG Motorcycle Division After Sales UX-VS-2 All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission. Errors and omissions excepted; subject to technical amendment.
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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.
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Usage Each chapter starts with the list of contents. The list of contents is followed by the Technical Data table. Chapter 00 “Maintenance and general instructions” details the handover checklist and lists all tightening torques and operating fluids. Key to symbols In this Workshop Manual for the K 1200 LT model, the following symbols are used; their meanings are explained in the table.
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Contents Group / Chapter 00 Maintenance and general instructions 00.1 11 Motor 11.1 12 Engine electrics 12.1 13 Fuel preparation and control 13.1 16 Fuel tank and lines 16.1 17 Radiator 17.1 18 Exhaust system 18.1 21 Clutch 21.1 23 Gearbox 23.1 31 Front fork 31.1 32 Steering 32.
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Group / Chapter 33 Rear wheel drive 33.1 34 Brakes 34.1 36 Wheels and tyres 36.1 46 Frame 46.1 51 Equipment 51.1 52 Seat 52.1 61 General electrical equipment 61.1 62 Instruments 62.1 63 Lights 63.1 65 Radio and optional extras 65.
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Mechanic’s signature BMW Annual Service Order No. BMW Inspection every 20,000 km (12,000 miles) Licence plate No.
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BMW AG Motorcycle Division Pre-delivery check K 1200 LT Customer Licence plate No. Order No.
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00 00 Maintenance and general instructions Tightening torques and Table of operating fluids Pre-delivery check Maintenance Contents Tightening torques Page ......................................................................................................................7 Table of operating fluids .........................................................................................................19 00.
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Pre-delivery check Contents - Pre-delivery check Overview: K1200LT packing materials Page ...........................................................................21 Checking the shipping crate for damage .....................................................................22 Damage discovered in Germany ............................................................................................
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Contents - Pre-delivery check Installing the windscreen cover ..............................................................................................35 Checking and adjusting the motorcycle ........................................................................35 Checking the function of side stand contact switch Adjusting the seat Page .....................................................35 ......................................................................................................
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Maintenance Contents - Maintenance Key to maintenance intervals General instructions ..............................................................................................38 .................................................................................................................39 Pushing the motorcycle onto a workshop platform High idle speed Page .......................................................39 .................................................................................
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Contents - Maintenance Page Checking the front/rear brake fluid level ......................................................................48 (Inspections I, II and III) ......................................................................................................................48 Checking the front brake fluid level ......................................................................................48 Checking the fluid level with brake fluid reservoir open ................................
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Contents - Maintenance Page Battery ..............................................................................................................................................63 (Inspections III and IV) .......................................................................................................................63 Check battery acid level and add distilled water if necessary; inspect battery terminals and clean and grease them if necessary .....................................................
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00 Tightening torques Model K 1200 LT Connection Nm 11 Engine Cylinder head Cylinder head bolts Joint torque Wrench angle 20 Oiled before installation 90° Cylinder head cover 9 Heat shield for cylinder-head cover 5 Coolant stub pipe 9 Intake stub pipe 9 Split conrods Split-conrod bearing Wrench angle 20 80° Crankshaft Rotor flange 50 Main bearing 50 Cover, crankcase 9 Freewheel Cover plate 10 Engine block Collared bearing, output shaft 40 Needle bearing, output shaft 20 Lower
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Model K 1200 LT Connection Nm 11 Engine Camshafts Bearing cap 10 Chain sprockets 56 Intermediate flange Thrust plate, driver to intermediate flange 9 (clean thread + Loctite 243) Driver to auxiliary shaft 50 Intermediate flange to engine block 9 Timing case Chain tensioner to cover of timing case 9 Screw plug for chain tensioner 9 Timing case cover 9 Oil/water pump Water-pump impeller to pump shaft 33 Water-pump temperature sensor 9 Oil pressure switch 35 Oil pressure relief valve
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Model K 1200 LT Connection Nm 12 Engine electrics Spark plugs 20 Ignition coil Ignition coil to mounting plate 8 Mounting plate to intermediate flange 9 Cover, shield housing 5 Ignition signal sensor Rotor 4 Magnetic gate 6 Cover, ignition sensor 9 Alternator Mount to intermediate flange 20 Driver housing to alternator shaft 50 Connector, lead B+ 10 Connector, lead D+ 2 Starter motor Starter motor to gearbox 6 Pinch bolt, starter-motor housing 6 Positive lead to starter motor
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Model K 1200 LT Connection Nm 16 Fuel tank and lines Union nut, fuel-pump unit 30 Roll-over valve 3 Immersion-tube sensor 6 Fuel tank to frame M 8 21 Bridge to frame M 8 21 Bridge to frame M 6 9 17 Radiator Hose clips Hand-tight Fan to radiator 2 (clean thread + Loctite 2701) Water pump temperature sensor 9 Coolant stub pipe to cylinder head 9 18 Exhaust system Oxygen sensor to exhaust system 45 Exhaust system to cylinder head 22 Exhaust mountings Retaining plate to pivot mount
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Model K 1200 LT Connection Nm 21 Clutch Clutch-lever fitting to handlebar 5 Grub screw in filler adapter 10 Filler adapter to breather line 18 (clean thread + Loctite 243) Clutch housing to output shaft initial torque release second torque wrench angle 140 50 60° Cover to clutch housing 18 Lines to clutch slave cylinder 7 Clutch slave cylinder to gearbox 9 Pressure line to clutch fitting 18 Connector, pressure line 10 23 Transmission Oil drain plug 55 Oil filler plug 30 Speed senso
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Model K 1200 LT Connection Nm 31 Front forks Fork bridge to frame (nut micro-encapsulated) 130 (clean thread + new nut or Loctite 2701) Fork stanchion to fork bridge 45 Steering damper to slider tube bridge (screw micro-encapsulated) 21 (clean thread + new screw or Loctite 243) Steering damper to leading link 21 (clean thread + new screw or Loctite 243) Leading link to fork slider bridge (nut micro-encapsulated) 130 (clean thread + Loctite 2701) Ball joint to fork slider bridge 230 Leading l
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Model K 1200 LT Connection Nm 33 Rear wheel drive Oil drain plug 23 Oil filler plug 23 Speed sensor mount 5 Threaded ring 118 (clean thread + Hylomar SQ 32) Nut, bevel drive pinion 200 (clean thread + Loctite 270) Housing cover to housing 35 Rear wheel drive to swinging arm Reaction link to rear wheel drive 43 Reaction link to frame 43 Free bearing stud 7 Fixed bearing stud 160 Locknut 160 Swinging arm to frame Fixed bearing stud 160 Lock ring 160 Threaded ring, right 200 Thr
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Model K 1200 LT Connection Nm 34 Brakes Front brake Brake calliper to fork tube 40 Brake disc to front wheel 21 (clean thread + Loctite 243) ABS sensor 4 Grubscrew in filler adapter 10 Filler adapter in brake calliper 18 (clean thread + new filler adapter or Loctite 243) Vent screw in brake calliper 10 Brake-lever fitting to handlebar 5 Holder for brake line to sliding tube 4 (clean thread + Loctite 243) Brake lines to frame/slider tube M 6 9 Banjo bolts for brake line 18 Rear brake
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Model K 1200 LT Connection Nm 36 Wheels and tyres Rear wheel mount Initial tightening Final tightening 50 105 Quick-release axle, front wheel Initial tightening Final tightening 19 30 Pinch bolt, quick-release axle 21 46 Frame Frame Engine cross members to main frame 74 Engine cross members to engine 41 Transverse tube to main frame 41 Torsion stop, swinging-arm bushings Fitted flush with bushing (clean thread + Loctite 243) Skirt bracket M 8 21 Crash bar to skirt bracket 9 Lifter hand
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Model K 1200 LT Connection Nm 46 Frame Footrests Footrest system front to frame 21 Footrest system rear to frame 21 Footrest rubber to footrest 4 Shift lever to footrest plate 41 (clean thread + Loctite 243) Footbrake lever to footrest plate 41 (clean thread + Loctite 243) Stop, footbrake lever 7 Stop screw, return spring for footbrake lever 5 Rear section, side cases and top case Rear carrier to rear frame 9 Cover, rear carrier to rear frame 9 Cover, rear carrier to case 1 Side case
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Model K 1200 LT Connection Nm 51 Equipment Non-removable screw for ignition/steering lock 21 Lock, tank cover to bridge 5 Locking mechanism, front seat to rear frame 5 52 Seat Bridge, seat to frame M 6 9 Bridge, seat to frame M 8 21 Front hinge, seat to bridge 9 Seat, front, to carrier plate 5 Gas-filled strut to carrier plate for seat, front 21 Seat, rear, to rear frame 9 Backrest, rear, to top case 5 61 General electrical equipment Retaining plate for fanfare horn to fairing bracke
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Model K 1200 LT Connection Nm 62 Instruments Instrument cluster to fairing bracket 6 63 Lights Headlight to upper section of fairing 2 Rear light cluster to case trimmer 5 65 Radio and optional extras Clamping nut, stub aerial 3 Aerial holder to frame 9 Retaining plate for cruise control system to fairing bracket 8 Holder for temperature sensor to upper section of fairing 2 00.
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Table of operating fluids Item Use Order number Quantity Staburags NBU 30 PTM High-performance lubricating paste 07 55 9 056 992 75 g tube Optimoly MP 3 High-performance lubricating paste 07 55 9 062 476 100 g tube Optimoly TA High-temperature assembly paste 18 21 9 062 599 100 g tube Silicone grease 300, heavy Damping grease 07 58 9 058 193 10 g tube Retinax EP2 Wheel, steering head and taper roller 83 22 9 407 845 100 g tube bearing grease Contact spray Contact spray 81 22 9 400 208 30
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00.
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Overview: K1200LT packing materials 00.
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Checking the shipping crate for damage • When the motorcycle arrives, check the crate immediately for damage and, if necessary, examine the contents for consequential damage. Damage discovered in Germany • • • Note the damage on the delivery slip. Read the information sheet on damage in transit. Notify the supplier without delay (e.g. freight company or DB) and also Bavaria Wirtschaftsagentur GmbH Abteilung ZW - 12 80788 München Tel. 089/14327-632 Fax.
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KLPD9001 Unpacking the motorcycle • • • – – • Lever off the cover. Cut the plastic sheet open and pull it off. Take out the separate packs of items: windscreen, skirt, centre engine spoiler - C left-hand side engine spoiler - D Use a crowbar to pry off the cross-struts. e Caution: Remove nails projecting from the base of the crate or lying on the base or on the floor. • Dispose of the packing materials in an environmentally responsible manner as described in Service Information 23/91 - Sales.
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Installing the front wheel e Caution: Protect trim panel parts with a material such as foam to prevent damage from straps and hoists. 46 5 640 46 5 650 KLPD0050 e Caution: Do not scrape the wheel – mask it off if necessary. Do not tilt the brake calliper. There is a risk of damage to the brake pads. L Note: Do not apply handbrake lever with brake callipers removed/front wheel removed. • • KLPD0011 e Caution: Support the motorcycle to prevent it toppling sideways.
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4 1 2 3 5 6 KR360010 • • • • • • • Remove quick-release axle (1). Lightly grease the quick-release axle (1) and bearing cage (3) and spacer bushes (4) with Shell Retinax EP2. Fit the bearing cage (3) and spacer bushes (4) on the front wheel. Tighten the retaining screw (6). Clean the brake discs. Install the brake callipers. Check the ABS sensor gap and adjust if necessary. ABS sensor gap: ........ 0.45...0.55 mm (0.018...0.022 in) X Tightening torques: Quick-release axle threaded connection ......
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General instructions Inspecting motorcycle for damage Pushing the motorcycle onto a workshop platform • • d Warning: The springs securing the side stand in position can catch as you are pushing the motorcycle onto a workshop platform. This could cause damage to the motorcycle and the workshop platform, or the motorcycle could topple to the side opposite the side stand. • • • • Lift the seat at the front. • – – – Examine the motorcycle for faults.
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1 3 2 KL460100 Installing remaining items on motorcycle Installing the mirrors Installing the front mudguard • • • • • • Release the fastener (2). Insert the bushes (3). Fit the front wheel mudguard. Screw in the fastener (2). Tighten the fasteners (1). Tighten the fastener (2). X Tightening torques: Front mudguard to slider tube bridge M6 ....... 9 Nm Front mudguard to sliding tube M6 ................
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1 KL460072 Installing the footrests Installing the rear right footrest and footrest plate Installing the rear left footrest plate L Note: The front fastener (1) (long pointed-top screw) on 2 the left-hand footrest plate also serves as the anchorage point for the battery bracket. • • Release the front fastener (1). Install the footrest plate using three mounting bolts. 3 X Tightening torque: 4 Footrest plate to frame .................................
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1 2 3 4 9 8 7 Installing the engine spoilers • • • • • • • • 5 6 Installing the skirts Install the socket (3) with nut in the left-hand engine spoiler. Install rubber clip-on nuts (1) at rear of each side spoiler. Install three clip-on nuts (6) in each side spoiler (5, 9). Position four clip-on nuts (7) in the centre engine spoiler (8). Install the left engine spoiler (5). Insert the connector (2) for the socket (3) into the left engine spoiler. Install the right engine spoiler (9).
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2 1 3 4 5 6 7 KL460250 Installing the top case • • • • • Fit the lock cylinder. Raise the seat. Remove the rear seat. Open the top case. Release the knurled screw (7). d Warning: Support the lid to prevent it falling closed. • • • • • • Support the cover (1). Detach the control cable from the underside of the case. Use a screwdriver to unclip the removable lining from the lock. Detach the Velcro strip (6) from the rear panel. Remove the lining.
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1 2 3 5 4 6 KLPD0070 • • • • • • Clip the cables for the radio remote control and the loudspeaker into the holders (1). Insert the top case plug connectors for the radio remote control (3) and the loudspeaker (2). Insert the removable lining and snap into place. Fit the knurled screw with the control cable. Plug in the connector (4) for rear seat heating, if applicable. Install the rear seat. X Tightening torque: Top case to rear frame ...................................
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Checking brake fluid level e Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint. Front brake – KL000340 Place the motorcycle on its centre stand so that it is level. 1 2 e Caution: The motorcycle may only be ridden with the protective cap fitted on the positive battery terminal. • • • • Close the protective cap on the positive battery cable. Reconnect the negative battery cable. Install the battery tray.
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• Remove the reservoir cap together with the diaphragm. Rear brake – • Place motorcycle on its centre stand. Open the right-hand side case. MAX MAX KL000110 • • Check brake fluid level. Top up the fluid level and, if necessary, check the brake system for leaks if the brake fluid level is below the “MAX” mark with new brake pads. Required level:............................................... MAX • Installation is the reverse of the removal procedure: pay particular attention to the following.
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Checking clutch fluid level Checking tyre pressures – • • Place the motorcycle on its centre stand so that it is level. Turn the handlebars to full right lock. L Note: The level of fluid in the expansion tank rises as the clutch lining wears. Check/correct tyre pressures. Tyre pressures: One-up................................. front 2.5 bar (35.6 psi) One-up.................................. rear 2.9 bar (41.2 psi) Two-up ................................ front 2.5 bar (35.6 psi) Two-up .............
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1 2 3 KL460140 Installing the windscreen Checking and adjusting the motorcycle • • • Checking the function of side stand contact switch Slightly raise the windscreen linkage. Install windscreen and retaining plate (3). Tighten the four screws (1) (micro-encapsulated). L Note: It may be necessary to bend the inner clips (2) to ensure that the plate retains the windscreen properly. • • • – • – Installing the windscreen cover • Clip the windscreen cover (2) from the outside (arrow) inwards.
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Checking headlight beam angle, adjusting if necessary Lateral adjustment Vertical adjustment • Set suspension preload to “LOW” (turn counterclockwise). 2 L Note: Make sure that the adjuster on the instrument-panel cover is at the “UP” position (turned counter-clockwise as far as it will go). • If necessary, turn the adjuster on the instrument panel counter-clockwise as far as it will go.
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Final inspection and function check • • • • • • • – – – – – – – – – – – • • • – – – – • • • • Fill up with fuel. Check engine oil when engine is cold, top up if necessary. Check clutch. Check gear shift action. Check reverser.
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Key to maintenance intervals Maintenance intervals consist of the first Inspection (after the first 1000 km/600 miles), the BMW Service, BMW Inspection and BMW Annual Service. In this Workshop Manual, the individual maintenance intervals are shown by the following codes: Inspection 1000 km/600 miles BMW Running-in Check after the first 1000 km/ 600 miles. — — — — BMW Service After the first 10,000 km/6000 miles and each additional 20,000 km/12,000 miles (at 18,000 miles ... 30,000 miles ...
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General instructions Removing the aerial Pushing the motorcycle onto a workshop platform d Warning: The springs securing the side stand in position can catch as you are pushing the motorcycle onto a workshop platform. This could cause damage to the motorcycle and the workshop platform, or the motorcycle could topple to the side opposite the side stand. • 3 2 Lift the seat at the front. 1 KL510010 e Caution: Take care not to damage the cap when removing.
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Reading the fault code memory with the MoDiTeC Checking throttle cable play, adjusting if necessary (Inspections I, II, III and IV) (Inspections I and III) L Note: Loss of power to the Motronic control unit, e.g. as a result of the battery being disconnected, deletes all entries (e.g. faults, adaptations) in the memory. • • • Open the throttle twist grip fully at different handlebar positions and then release. Turn the handlebars to full left lock.
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• d Warning: Observe the hazard avoidance instructions for running internal combustion engines in enclosed spaces. • • • Warm up the engine to its normal operating temperature; radiator fan starts to run. Check the freedom of movement of the throttle twist grip. When released, the twistgrip must return to the closed position by itself and with an audible click. Check the routing of the cables if the throttle twist grip does not return to the closed position or if it is stiff.
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Changing engine oil, replacing oil filter element (Inspections I, II, III and IV) Replace oil and oil filter at least once a year. If the motorcycle is ridden only for short distances or at outside temperatures below 0 °C (32 °F), this task must be performed every 3 months or every 3,000 km (1,800 miles) at the latest. d Warning: Observe the hazard avoidance instructions for running internal combustion engines in enclosed spaces.
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Changing gearbox oil – – Change the gearbox oil every two years at the latest (Inspection III) a L Note: Only drain gearbox oil when the gearbox is at oper- a • • Place the motorcycle on its centre stand so that it is level. Remove engine spoiler. ....................................................See Group 46 Remove the front right footrest. Remove the exhaust bracket on the centre stand mounting bracket. ...................................................
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• • • • Reinstall the oil drain plug. Fill with gearbox oil. Reinstall the oil filler plug with a new sealing ring. Install the exhaust bracket. e Caution: Dispose of used oil in an environmentally friendly manner. X Tightening torques: Oil drain plug................................................ 55 Nm Oil filler plug ................................................. 30 Nm Foot rest mounting ....................................... 21 Nm Fastener exhaust mounting bracket to bracket ...................
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Brake pads/brake discs Rear brake pads Checking brake pads and discs for wear and replacing if necessary (Inspections II and III) Checking brake pads for wear d Warning: Never permit brake pads to wear past minimum permissible thickness. Always replace pads as a complete set. 1 2 Front brake pads KL000060 e Caution: Do not scrape the wheel – mask it off if necessary. • – • Remove the brake calliper. Release the brake line from the clips (arrows) on the rear-wheel drive.
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Replacing brake pads Front brake e Caution: Do not separate the two halves of the brake calliper. Do not scrape the wheel – mask it off if necessary. – Remove the brake calliper. 34 1 500 KL000080 • • 1 • 2 KR340270 • • • Remove the split-pin keeper (1) from retaining pin (2). Remove retaining pin (2). Remove brake pads by pulling downwards. Installation is the reverse of the removal procedure: pay particular attention to the following.
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2 2 1 3 3 KL000200 Rear brake e Caution: Do not separate the two halves of the brake calliper. – • • • Remove the brake calliper. Remove the split-pin keepers (2) from retaining pins (3). Pull out the retaining pins (3) and remove the retaining plate (1). Remove brake pads. 34 1 500 KL000090 • • Installation is the reverse of the removal procedure: pay particular attention to the following. Before installing the brake calliper, force the pistons fully back with resetting tool, BMW No. 34 1 500.
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Checking the front/rear brake fluid level 1 (Inspections I, II and III) Checking the front brake fluid level e KL000160 Caution: The fluid level in the brake fluid reservoir must be at the MAX mark with new brake pads. It is not possible to check the maximum fill level at the inspection glass. The fluid level must be checked by opening the brake fluid reservoir. – • • Note the installed position of the retaining plate (1). Check the function of the brake system.
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Checking the fluid level with brake fluid reservoir open MAX e Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint. – • • • Place the motorcycle on its centre stand so that it is level. Remove the top and bottom right handlebar trim panels. Remove the combination switch. Turn the handlebars to full left lock. KL000110 Required level with new brake pads ....................................
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Checking the rear brake fluid level (Inspections I, II and III) L Note: The volume of brake fluid (MIN/MAX) is sufficient for Checking operation of brake system and freedom from leaks, repairing/ replacing if necessary (Inspection III) pad thicknesses from new to the wear limit. It is not normally necessary to add fluid to compensate for pad wear. A level below MIN indicates the possibility of other faults. • – • • Place motorcycle on its centre stand. Open the right-hand side case.
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Changing brake fluid and bleeding brake system Change the brake fluid once a year at the latest (Inspection IV) L Note: This description applies for the brake filling and bleeding unit with extraction of the brake fluid by a partial vacuum at the brake calliper. If other devices are used, comply with their manufacturers’ instructions. 34 1 500 KR340340 Front brake – Place the motorcycle on its centre stand so that it is level.
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• • • Rotate the brake fitting so that the sealing surface on the reservoir cap is horizontal when viewed from the side. Tighten the clamping screw. Remove the reservoir cap together with the diaphragm. MAX e Caution: During the bleeding process, do not permit the brake fluid level to drop below the “MIN” mark, or else air will be drawn into the brake system. Bleed the system again if this happens. • • • Open the bleed screw by half a turn.
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Bleeding the front right brake calliper L Note: Remove the grubscrew from the filler adapter and install a bleed screw instead so that the brakes can be bled. d Warning: The motorcycle must not be ridden without the grub screw screwed into the filling port. Take care when removing the bleed screw and installing the grub screw: do not permit brake fluid to come into contact with the brake pads or other parts of the motorcycle. • • 1 2 • • Remove the bleed screw.
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Rear brake – – a • Place the motorcycle on its centre stand so that it is level. Remove the right-hand battery cover. ....................................................See Group 46 Remove rear seat. During the bleeding process, do not permit the brake fluid level to drop below the MIN mark, or else air will be drawn into the brake system. Bleed the system again if this happens.
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Bleeding the brake calliper e Caution: Dispose of old brake fluid in an environmentally friendly manner. Brake fluid grade .........................................DOT 4 X Tightening torque: Bleed screw ................................................. 10 Nm Checking clutch fluid level KL000300 • • Connect the brake bleeding device to the brake calliper on the rim side (arrow). Open the bleed screw by half a turn.
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Changing the clutch fluid (every 40,000 km/24,000 miles) Change the clutch fluid every 2 years at the latest (Inspection III) L Note: This description applies for the brake filling and bleeding unit with extraction of the brake fluid by a partial vacuum at the brake calliper. If other devices are used, comply with their manufacturers’ instructions. – – Place the motorcycle on its centre stand so that it is level. Remove the right skirt section.
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• • e Caution: Pull the protective hose over the filling port. Secure the bleed hose to the right skirt with a cable tie. During the bleeding process, do not permit the brake fluid level to drop below the MIN mark, or else air will be drawn into the brake system. Bleed the system again if this happens. • Draw off brake fluid until it emerges clear and free from air bubbles. e Caution: Dispose of old brake fluid in an environmentally friendly manner.
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1 2 3 KL160021 Replacing fuel filter (every 40,000 km/24,000 miles) d Warning: Comply with safety precautions when handling or working with fuel. (Inspection III) L Note: If the fuel is of poor quality, replace the fuel filter • Removing the fuel pump unit every 20,000 km (12,000 miles). • – • a Remove fuel tank. ....................................................See Group 16 00.58 Drain fuel tank. Release union nut (3) using wrench, BMW No. 16 1 710.
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Removing and installing fuel filter Installing the fuel-pump unit • • • Open the retainers (4). Disconnect fuel hoses (1, 3) from fuel filter (2). Install the fuel-pump unit complete with gasket in the fuel tank. e Caution: Note correct direction of flow through fuel filter. 3 2 1 KL160024 4 L Note: 4 Make sure that the arrow on the underside of the fuel tank points directly toward the arrows on the fuel-pump unit. • • Tighten the union nut with wrench, BMW No. 16 1 710. Install the fuel tank.
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1 KL170010 Checking and topping up, if necessary, coolant level and concentration • e (Inspections I and III) L Note: Only correct the coolant level when the engine is Caution: Anti-freeze protection must be guaranteed to at least -30 °C (-22 °F). Use only nitrite-free long-term antifreeze and corrosion inhibitor. Do not top up expansion tank past the MAX mark (arrow). • • cold. • Open the left-hand side case. Lift the seat at the front. Remove the cap from the expansion tank (1).
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Changing coolant (Inspection IV) L Note: Change the coolant every 2 years at the latest Draining coolant – a – a • • Remove left fairing sections, left battery cover and centre section of engine spoiler. ....................................................See Group 46 Remove tank cover. ....................................................See Group 46 Open the filler cap on the left radiator. Position a drip tray beneath the oil/water pump.
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Filling coolant system • Reinstall expansion tank and retighten securing screws. e Caution: Make sure that the vent hose is not pinched or kinked. • • Refit vent hose, turn bolt on hose clip forwards and tighten. Screw in water pump temperature sensor and tighten. KL000400 • • • Turn the engine over on the starter, kneading the hoses to the coolant outlet and the water pump (arrows). Top up with coolant to the MAX mark if necessary. Installation is the reverse of the removal procedure.
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Battery • (Inspections III and IV) • Check battery acid level and add distilled water if necessary; inspect battery terminals and clean and grease them if necessary • • d Warning: Battery acid is highly caustic. Protect the eyes, face and hands and also paintwork and clothing. • Adding distilled water – – Checking battery acid level Open cover cap for the positive battery terminal, disconnect positive battery lead and isolate. Release the fasteners (1) on the battery tray (2).
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KR130010 KL000340 • Guide the breather hose through the eyelet (see arrow) in the battery holder to the outside. • Remove fasteners (arrows) and take off cover. L Note: Disconnecting the battery clears all entries (such as errors, adaptations) from the Motronic control unit memory. The loss of the adaptations may sometimes lead to engine performance being temporarily impaired when the engine is restarted. Motronic restores the lost adaptations itself over the following operating hours.
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Greasing the side stand e Caution: (Inspections II, III and IV) Make sure the motorcycle cannot topple by using an assembly crane, BMW No. 46 5 640, and crossbar, BMW No. 46 5 650. • • – Carefully hoist the motorcycle with the lifting gear, BMW No. 00 1 510, until the centre stand can be freely extended and retracted. Check whether the centre stand retracts automatically. The centre stand must be lubricated if it does not retract automatically.
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3 w 1 3 2 4 4 1 KR460270 e Caution: e Caution: • Lubricant: For sleeves ................................ Shell Retinax EP 2 Screws (1) are secured with thread-locking compound. Do not overheat the O-rings (3) when softening the thread-locking compound. • • • • • Using a hot-air gun and working from the inside, carefully soften the thread-locking compound on screws (1) on left and right. Remove both screws (1). Remove circlip (2) on left. Press out sleeve (4) on the left and right.
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Checking the steering damper (Inspections II and III) • • Turn the handlebars to full left lock. Waggle the front of the casing to and fro to check the play in the piston rod and on the ball head. Cleaning the inductive sensor on the rear wheel (every 40,000 km/ 24,000 miles) Clean the inductive sensor on the rear wheel every two years at the latest (Inspection III) Checking tightness of rear wheel studs (Inspection I) • Tighten the rear wheel studs with a torque wrench.
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Checking valve clearances, adjusting if necessary L Note: (Inspection III) Turn the camshaft in the direction of rotation or press until the oil is forced out of the chain tensioner and the pin for the chain tensioner can be pushed in as far as the stop. Checking valve clearances e Caution: Never unscrew the spark plugs before measuring valve clearances. Oil-carbon particles could become lodged behind the exhaust valve head and falsify the measurement.
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1 2 3 4 11 3 700 KR110270 • • • • • • • Turn the camshafts until the tips of the cams are clear. Remove the bearing caps (2) for the thrust bearings first, to prevent tilting. Uniformly release studs of radial bearing caps (3) and remove the bearing caps. Take out the camshafts. Use a rubber extractor, BMW No. 11 3 251, to withdraw the bucket tappets from the cylinder head. Oil the replacement tappets lightly and insert. Oil the camshaft bearing journals. Identification marks, camshafts Inlet .......
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• Turn the engine over and check the relative positions of the camshaft chain sprockets and the crankshaft (at TDC). • • • Tighten all screws until seated. Tighten the screws in diagonally opposite sequence, working from the inside outwards. Install the cover plate. X Tightening torques: Cylinder head cover ....................................... 9 Nm Spark plugs.................................................. 20 Nm Cover plate screws ........................................
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Replacing spark plugs Final inspection with road safety and functional check (Inspection III) (Inspections I, II, III and IV) 2 3 Road safety check • Check wheels and tyres. • Check tyre pressures and correct if necessary. • Wait at least 10 minutes after a test run to check and correct the engine oil level. 1 Tyre pressures One-up................................. front 2.5 bar (35.6 psi) One-up.................................. rear 2.9 bar (41.2 psi) Two-up ................................
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00.
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11 11 Motor Contents Page Technical Data ............................................................................................................................... 5 Cutaway drawing of engine, K 1200 LT ..........................................................................11 Preparatory work with engine installed .........................................................................13 …for removal of combined oil/water pump ...............................................................
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Contents Page Removing, disassembling and assembling cylinder head ..........................................22 Removing camshafts .........................................................................................................................22 Removing bucket-type tappets .........................................................................................................22 Removing cylinder head ...............................................................................................
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Contents Assembling engine Page ....................................................................................................................37 Installing output shaft ..................................................................................................................37 Assembling the crankcase ................................................................................................................37 Installing oil mesh strainer ...............................................
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11.
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11 Technical Data K 1200 LT Engine, general Engine design In-line four-stroke engine installed longitudinally, with double overhead camshafts, liquid cooling and electronic fuel injection. Location of engine number At lower rear right of engine block Cylinder bore mm (in) 70.5 (2.77) Stroke mm (in) 75 (2.95) Number of cylinders 4 Effective displacement cc 1171 Compression ratio 10.8 : 1 Power output kW 72 Max.
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Technical Data K 1200 LT Oil pump Oil pump Gear-type Timing chain Type Pre-stretched, endless single roller chain with 128 links Valves Included valve angle Inlet ° 20.5 Exhaust ° 19.5 Valve clearances with engine cold (max. 35 °C/95 °F) Inlet valve mm (in) 0.15…0.20 (0.059…0.079) Exhaust valve mm (in) 0.25…0.30 (0.010…0.012) Valve timing for 3 mm (0.
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Technical Data K 1200 LT Valve seat Valve seat angle Inlet ° 45 Exhaust ° 45 Valve seat width Inlet mm (in) 0.95…1.25 (0.037...0.049) Wear limit mm (in) 2.5 (0.10) Exhaust mm (in) 1.15…1.45 (0.045...0.057) Wear limit mm (in) 3.0 (0.12) Valve seat extl. dia. (dimension for machining seat) Inlet mm (in) 25.60…26.00 (1.007...1.023) Exhaust mm (in) 22.15…22.55 (0.872...0.887) Seat ring dia. (oversize +0.2 mm/+0.008 in) Inlet mm (in) 27.59…27.72 (1.086...1.091) Exhaust mm (in) 25.09…25.
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Technical Data K 1200 LT Camshaft Inlet camshaft ° 244 Exhaust camshaft ° 232 Guide bearing dia. Wear limit mm (in) 29.970…30.000 (1.1799...1.1811) mm (in) 29.95 (1.179) Guide bearing bore mm (in) 30.020…30.041 (1.1819...1.1827) Camshaft bearing bore mm (in) 24.020…24.041 (0.9457...0.9465) Radial clearance Guide bearing mm (in) 0.020…0.071 (0.0008…0.0028) Camshaft bearing mm (in) 0.020…0.071 (0.0008…0.0028) Cam base circle dia. mm (in) 30 (1.18) Cam height, inlet mm (in) 37.989 ... 38.
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Technical Data K 1200 LT Connecting rod Big end bearing with bearing shell Radial clearance mm (in) 0.030…0.066 (0.0012...0.0026) Wear limit mm (in) 0.130 (0.0051) Piston pin bore dia. with bushing mm (in) 17.006…17.017 (0.6695...0.6699) Distance between centers mm (in) 130.9…131.1 (5.15...5.16) Permissible weight difference g (oz.) ± 4 (± 0.14) Cylinders Bore A mm (in) 70.495…70.505 (2.7754...2.7758) Wear limit mm (in) +0.05 (+0.002) B mm (in) 70.505…70.515 (2.7758...2.
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Technical Data K 1200 LT Piston rings 1st groove Rectangular-section ring Height mm (in) 0.975…0.990 (0.0383...0.0389) Wear limit End gap mm (in) 0.90 (0.035) mm (in) 0.10…0.30 (0.004…0.012) Wear limit Side clearance Wear limit mm (in) 1.50 (0.059) mm (in) 0.030…0.065 (0.0012...0.0026) mm (in) 0.20 (0.007) 2nd groove Taper-face oil-control ring Height mm (in) 1.195 ... 1.170 (0.0470...0.0461) Wear limit End gap mm (in) 1.10 (0.043) mm (in) 0.10…0.30 (0.004…0.
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Cutaway drawing of engine, K 1200 LT KL119000 11.
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11.
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Preparatory work with engine installed …for removal of combined oil/water pump • a • a • a Remove engine spoiler. ....................................................See Group 46 Drain coolant. ....................................................See Group 17 Drain engine oil. ....................................................See Group 00 …for removal of timing case cover, removal of timing chain e Caution: Disconnect ground lead from battery and insulate.
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...for removal of cylinder head Removing/installing engine e Caution: Disconnect ground lead from battery and insulate. Removing engine • a • Remove left and right fairing side sections and engine spoilers. ....................................................See Group 46 Remove left-hand skirt bracket. d Warning: Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressurised. • a • a • • • a • a • a Remove fuel tank. ................................
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Groups: rear-wheel drive, wheels and tyres • Remove rear-wheel inductive sensor. • Remove rear-wheel brake caliper. • Use cable ties to secure brake caliper and inductive sensor to frame. • Remove rear wheel. d Warning: Note high release torques. • Remove swinging arm. Groups: frame and clutch Remove transverse tube. Disconnect or open plug connections for engine and gearbox. • Remove switch for gear indicator, pull cable toward rear and remove.
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Installing engine • • Install the clutch. Secure engine to hoist, BMW No. 00 1 510, and disengage engine from stand, BMW No. 00 1 490. Groups: frame and gearbox e Caution: When maneuvering the engine below the motorcycle and raising and lowering the frame, always take care not to damage components or scratch surfaces. • • • • • • • • • • • • • • • • Install the alternator. Apply a coat of Optimoly MP 3 to the splines of the gearbox input shaft. Secure guide pins, BMW No.
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7 6 1 2 3 4 5 KL110060 Disassembling engine Removing, disassembling/assembling water pump Removing the oil/water pump • Disconnect oil pressure warning and water pump temperature sensor wires from switches. • Withdraw wires through hole in pump housing. • Remove pump housing cover (1) and loosen the gasket by tapping lightly with a plastic-headed hammer. • Remove the housing and loosen the gasket by tapping lightly with plastic-headed hammer. • Remove oil-pump gear (7).
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1 2 3 5 4 11 10 9 8 6 7 KL110071 Removing the oil pressure relief valve • Unscrew plug (1) and take out spring (3). • Pull valve piston (4) out with a magnet and examine it for damage. Installing the oil pressure relief valve • Oil valve piston (4) lightly and install. • Install spring (3) and tighten screw plug (1), fitted with new sealing ring (2). X Tightening torque: Oil pressure relief valve screw plug ..............
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2 3 1 4 5 KR110200 Removing timing chain cover Removing ignition pulse generator • Remove cover (5). • Remove gasket (4). Removing cylinder head cover L Note: Mark the position of the magnetic gate in relation to the engine block, or remove it in the top dead centre (TDC) position. 6 7 • • 8 Remove magnetic gate (1), noting the presence of semi-circular shims. Remove rotor (2) and take off adjusting disc (3).
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1 KL110020 • Use pin, BMW No. 11 6 740, to prevent chain tensioner (1) moving. L Note: Turn the camshaft in its normal direction of rotation until oil is forced out of the chain tensioner and the pin can be inserted all the way. Removing/installing sealing ring in timing case cover • Using a drift, drive the sealing ring inwards to remove. L Note: Remove traces of paint and clean the seat of the sealing ring. • • • Disconnect oil pressure switch and water pump temperature switch cables.
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1 2 4 3 5 6 KL110030 Removing the timing chain • e Caution: • Centre the piston in the cylinder (cylinder 1 approx. 90° before top dead centre), to avoid damage to the valves and piston. Turn the crankshaft in the counter-clockwise direction only. Remove the screws securing the chain sprokkets, holding the camshaft at the hexagon. Remove the chain sprockets and slide rail. Removing chain tensioner rail Remove the keeper (5) and washer (6). Remove tensioner rail (4).
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Renewing tensioning strap for chain tensioner rail Removing bucket-type tappets L Note: Make a note of which bucket-type tappets belong to which valves. • Use the rubber suction device, BMW No. 11 3 251, to pull the bucket-type tappets (1) out of the cylinder head. Removing cylinder head Remove the spark plugs and ignition cables. a ....................................................See Group 12 • L Note: KL110080 • Unclip the tensioning strap from the tensioner rail.
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Machining valve seat 11 1 740 D 11 1 748 B KR110290 • • Install the valve spring compressor, BMW No. 11 1 740. Use compressor cage, BMW No. 11 1 748. KR110310 D = valve diameter B = valve seat width e Caution: Centre the compressor cage in order to avoid da- • maging the tappet bores. • • Place the cylinder head on suitable blocks (arrows) to ensure adequate clearance for valve removal. Machine the valve seat with turning tool, BMW No. 00 3 530.
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Installing valve and valve stem seal L Note: If a valve is removed, the valve stem seal must be Removing/installing crankshaft gear and rotor flange renewed. • • Oil the stem when installing the valve. Insert the lower spring retainer. 1 11 2 821 KL110230 • Mount the retaining device, BMW No. 11 2 821, on the clutch housing as shown. KR110320 • • 3 Place a shrink-fit tube approx. 20 mm (0.79 in) long on the valve stem and heat it up. Drive in valve stem seal (1) with the assembly tool, BMW No.
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Removing crankshaft L Note: Remove the driver first if the intermediate flange is to be removed after the crankshaft. Removing big end bearings • Bring pistons 1 and 4 to BDC position. L Note: Make a note of which caps belong to which main bearings, and note the installed positions. Bearing caps 1 - 3 are marked for identification. Bearing 4 (thrust bearing) and bearing 5 are not marked. Cylinder 1 = timing end of engine. • • • Remove the bearing caps. Remove the final bolt.
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Checking piston dimensions 1st groove: Rectangular-section ring. 2nd groove: Taper-face oil-control ring; note pin for butt joint. 3rd groove: U-Flex ring with spring. L Note: The gap in the spring must be offset by 180° in relation to the Flex ring gap. Checking cylinder dimensions KL110190 • Use caliper gauge to measure the piston diameter at planes “A”. Dimension “A” .................................. 10 mm (0.4 in) • • – Measure piston ring edge clearances with feeler gauge.
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Assembling pistons and conrods • Note weight tolerances when replacing conrods: use only conrods of the same weight class. • Install only pistons of the same weight group. Weight tolerance ............................. ± 4 g (0.14 oz.) • Weigh the conrods to determine the weight class. Weight classes Class 0 1 2 3 4 5 6 7 • Weight in g (oz.) 413 ... 416.9 (14.578...14.716) 417 ... 420.9 (14.720...14.857) 421 ... 424.9 (14.861...14.998) 425 ... 428.9 (15.002...15.140) 429 ... 432.9 (15.143...15.
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Measure backlash at the countershaft Removing intermediate flange L Note: Abnormal noises, especially at low engine speeds, • could be due to excessive backlash between the crankshaft/countershaft gearing. a a • Remove the ignition coil. ....................................................See Group 12 Remove the clutch. ....................................................See Group 21 Removing driver e Caution: Always measure backlash with the engine cold.
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4 1 2 5 3 KR110090 Removing clutch housing e Caution: After unscrewing nut (1), do not strike the output shaft or turn the engine over, so that output shaft endplay cannot cause damage to the crankcase or pump housing. • • Removing intermediate flange • Use Torx socket T 30, BMW No. 00 2 600, to release the screws. • Remove the intermediate flange and loosen the gasket by tapping lightly with plastic-headed hammer. Unscrew nut (1) and remove thrust ring (2).
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1 2 3 4 KR110120 Disassembling/assembling intermediate flange Removing the driver bearing • Remove thrust plate (1). • Remove cup spring (2). • Remove ball bearing (3) with puller, BMW No. 00 8 570, and internal puller 21/3, BMW No. 00 8 574. • Remove retaining ring (4). Installing driver bearing • Install retaining ring (4). L Note: KR110130 Use temperature measuring device, BMW No. 00 1 900, to check heat rise. • • • • Heat the intermediate flange at the bearing seat to approx.
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Removing/installing shaft sealing ring for driver • If the intermediate flange has been removed, lever out the sealing ring. Removing countershaft and layshaft with freewheel 00 5 010 KR110140 • If the intermediate flange is installed, use puller, BMW No. 00 5 010, to remove the sealing ring. L Note: KR110690 • • Pull the countershaft and layshaft out of the crankcase together. Note special spring (arrow). Clean the sealing ring seat.
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5 6 4 3 2 1 KR110160 Disassembling/assembling freewheel Disassembling freewheel • Pull washer (6) and freewheel gear (5) off the layshaft (1). • Clamp the layshaft into a vice with soft jaws (smooth side down). • Remove cover plate (4). • Pull off freewheel cage (3). • Take out cup spring (2). • Press out the needle bearing. 11.
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Removing/installing needle bearing for layshaft and shaft sealing ring in crankcase Assembling freewheel Removing bearing 11 6 731 00 8 574 X • • X The inscription on the needle roller bearing faces down. Press the needle bearings into the freewheel gear, making sure that distance (X) from edge is uniform. Distance “X” ............ 0.2…0.6 mm (0.007...0.023 in) • • • • Install the cup spring with the larger diameter facing the layshaft.
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3 1 2 4 KR110440 Removing output shaft Removing oil sump • Remove the screws. • Loosen the gasket with light blows of a plasticfaced hammer and take off the oil sump. Removing/installing oil level sight glass • Using a large screwdriver, pierce the plastic window and lever out the oil level sight glass. L Note: Clean the sealing face. Removing the oil mesh strainer and oil filter • Remove the screw and pull off oil mesh strainer (1).
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3 1 2 4 5 6 7 8 9 10 11 KR110450 Disassembling/reassembling output shaft Disassembling output shaft • Remove needle roller race (1) and circlip (2). • Remove output shaft (3) from the damper housing (9) and remove rubber dampers (11). • Drive the output shaft out of the inner section of the damper (10) with a plastic-faced hammer. • • • • • Disassembling tensioning gear Clamp the damper housing into a vice with soft jaws, to take the load off circlip (4). Remove circlip (4) with circlip pliers.
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Assembling tensioning gear • Insert the tensioning spring. • Engage the tensioning spring on the pin in the tensioning gear and turn it clockwise with the counter-holder, BMW No. 12 4 600, until the pin of the tensioning gear engages the hole in the gear. • Clamp the tensioning gear with damper housing in a vice with soft jaws. L Note: Use temperature measuring device, BMW No. 00 1 900, to check heat rise. • Heat the ball bearing to approx.
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6 4 3 1 5 9 2 7 Assembling damper • Insert the rubber dampers (7) into the damper housing (6). L Note: New parts must be oiled lightly. KR110451 L Note: Make sure that the open end of the snap ring (arrow) is facing downward in the crankcase. • Install O-rings (8, 9) for the water and oil passages. Assembling the crankcase • • Push the retaining plate (4) onto the output shaft (3), slightly heat the inner part of the damper (5) and press it into position on the shaft.
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1 3 2 4 KR110440 • • • Mate the two halves of the housing. Insert screws (4) for shouldered bearing and screws (3) for needle roller bearing, and tighten alternately. Tighten the screws for the lower part of the crankcase. Installing oil sump X Tightening torque: Shouldered bearing...................................... 40 Nm Needle roller bearing .................................... 20 Nm Lower part of crankcase...............................
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Installing intermediate flange Installing intermediate flange Installing freewheel • Oil the needle roller bearing well. • Insert the freewheel into the crankcase helicalcut gear first. Installing countershaft KL110270 • • KR110690 e Caution: Insert the spring so that the large external diameter (arrow) projects upwards and is pre-loaded against the freewheel gear. • Insert the countershaft into the crankcase with the small gearwheel facing down.
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Installing clutch housing • Oil the internal splines of the clutch housing. • Place thrust washer in position between output shaft and intermediate flange; if necessary use a blob of grease to hold the thrust washer in position. Installing driver L Note: The driver can be installed only with the crankshaft installed. • • X Tightening torque: Driver ........................................................... 50 Nm 11 2 500 • • a 11 2 821 KL110240 Manoeuvre the clutch housing into position.
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Measuring crankshaft bearing play Measuring radial play • Turn the crankshaft to top dead centre at the bearing to be measured. • Take off the bearing cap. • Wipe off oil at the bearing journal and bearing shell. • Measure bearing play with Plastigage, BMW No. 00 2 590. KL110140 • • Compare the width of the strip with the scale (arrow) in order to determine bearing play. Remove all traces of Plastigage from the shaft journal and bearing shell. Radial play .. 0.020…0.056 mm (0.0007...0.
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Installing piston with conrod • • Turn the crankpin in question to bottom dead centre. Make sure that the pistons are in the same weight category. 11 2 500 e Caution: Note the pin for locating the end gap of the taperface oil-control ring in the 2nd groove. • • • • • • Space the piston ring gaps at approx. 120° offsets. Thoroughly oil the piston rings, piston skirt and cylinder wall. Insert the piston into the sliding sleeve, BMW No. 11 6 700.
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• Place the bearing cap in position and tighten the securing screws to 20 Nm. Checking dimensions of crankshaft • L Note: – Do not turn the crankshaft any more. • Use angle-of-rotation gauge, BMW No. 11 2 500, to tighten the big-end bearing screws another 80°. 2 X 1 Tightening torque: Big end bearings .......................................... 20 Nm Wrench angle ....................................................
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Installing cylinder head • L Note: Check that the engine block and cylinder head gasket are correctly aligned; if necessary use a whetstone to remove protruding edges of the gasket. Remove the bucket tappets before installing the cylinder head. Make a note of which bucket tappets belong to which valves. • • 6 8 3 1 9 Clean the cylinder head bolts and the threads in the engine block. Clean the sealing faces and check for surface irregularities and damage.
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Installing camshafts Identification marks, camshafts Inlet ................. 2 grooves behind the thrust bearing Exhaust .............1 groove behind the thrust bearing 11 3 700 Identification marks, camshaft bearing caps Inlet side ............................................odd numbers Exhaust side..................................... even numbers Consecutive numerical order from front (timing end) to rear. e Caution: Centre the pistons in the cylinders (cylinder 1 approx.
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1 2 4 3 5 6 KL110030 • • • Press the guide rail (3) with timing chain and bushing onto the locating pin. Install the snap rings (1) and washers (2) for the guide rail on the two locating pins. Slip the chain onto the crankshaft gear. 8 7 • • • • • • • • Install screw (7) until seated. Install guide rail (8). Press the tensioning rail (4) onto the locating pin and install washer (6) and keeper (5).
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Installing timing case cover • Introduce the cables for the oil-pressure switch and water temperature switch through the cable duct. 1 KR110810 KR110930 • • • Insert O-ring (1) for chain tensioner into timing case cover. Install chain tensioner in timing case cover. Prevent chain tensioner from moving with pin, BMW No. 11 6 740. • • • Install the timing case cover and tighten the securing screws. Make sure that the long screws are installed in the correct positions (arrows).
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2 1 KR110710 Installing ignition pulse generator • • • Mount adjusting disc and rotor on crankshaft and tighten. Reinstall magnetic gate (1) in its original position, as marked. Tighten screws (arrows) with washers and semicircular washers. X Tightening torque: Rotor .............................................................. 4 Nm Magnetic gate ................................................ 6 Nm e Caution: Set the ignition timing. 11.
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Installing combined oil/water pump • e Caution: Tighten the clutch housing before installing the oil/ Run the wires for the oil pressure telltale and water pump temperature sensor through the hole in the pump housing and connect them. water pump, so that the output shaft cannot damage the pump housing. KR110891 • KL110010 • • • • Check that sealing face of the pump housing is clean and degreased and apply a thin coat of Omni VISC 1002, see black line on sealing face with grey shading.
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Installing cylinder head cover • a Install the spark plugs and ignition leads. ....................................................See Group 12 X Tightening torque: Spark plug.................................................... 20 Nm • Install the cylinder head cover gasket with the half moons first. The marks at the front and rear of the gasket and the cylinder head cover must coincide.
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12 12 Engine electrics Contents Page Technical Data ............................................................................................................................... 3 Removing and installing Hall-effect transmitters Preparatory work .......................................................5 .............................................................................................................................5 Removing cover from Hall-effect transmitter ............................
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12.
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12 Technical Data K 1200 LT Starter motor Type Permanent-magnet motor Gear ratio 27:1 Power rating kW 0.7 Three-phase generator Type Three-phase AC generator Gear ratio 1:1.5 Drive direct Maximum output rating Maximum current W/V 840/14 A 60 Three-phase generator speed for start of charge min-1 1000 (24 A charge current) Max. operating speed min-1 18000 Spark plug Bosch XR 7 LDC Thread metric M 12 x 1.
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2 3 1 5 4 KR110200 Removing and installing Hall-effect transmitters Removing magnetic gate Preparatory work – a – – Remove left and right fairing side sections. ....................................................See Group 46 Remove centre and right sections of engine spoiler. Remove right skirt bracket. e Caution: Switch off the ignition and disconnect and insulate 6 the earth (ground) lead at the battery. – a – a – Remove fuel tank. ....................................................
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3 4 2 1 6 5 KR110200 Installing the magnetic gate • • • • • • Place adjusting disc (4) and rotor (3) on crankshaft, and tighten. Install magnetic gate (2) in the same position as previously marked. Install screws (1) with washers and semi-circular washers and tighten. Reconnect the plug connector in the electronic equipment box. Reinstall cables in their original positions and use cable ties to secure. Install the cover on the electronic equipment box.
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1 2 3 KL120030 Replacing spark plugs/ignition leads – a • • Remove left-hand side of engine spoiler. ....................................................See Group 46 Remove heat shield (3). Pull off spark plug caps with flat pliers. Removing and installing spark plugs • • 1 2 3 X Removing and installing ignition leads • • 3 1 4 Remove spark plugs with spark plug wrench, BMW No. 12 3 500. Installation is the reverse of the removal procedure. KR120160 Tightening torques: Spark plugs........
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1 4 2 3 KL120040 Removing and installing coil Motorcycles without shield housing e Caution: 2 3 Switch off the ignition and disconnect and insulate the earth (ground) lead at the battery. – a • • • • • Remove left side section of fairing and engine spoiler. ....................................................See Group 46 Remove left-hand skirt bracket. Disconnect ignition leads (4) from ignition coil. Press in the clips of the primary connection (2) and unplug the connector.
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5 4 3 1 2 6 7 9 8 KL120050 Motorcycles with shield housing Timing the ignition e Caution: Preparatory work Switch off the ignition and disconnect and insulate the earth (ground) lead at the battery. – a • • • • • • • Remove left side section of fairing and engine spoiler. ....................................................See Group 46 Remove left-hand skirt bracket. Remove screws (1) and lift off cover (2). Disconnect ignition leads (3) from ignition coil.
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• • • • 30 40 Setting timing without Motronic 70 90 80 0 60 10 50 20 00 2 580 Retighten magnetic gate (2, 3). Check that ignition timing is correct. Turn the engine in its normal direction of rotation. With the piston at 0.24 mm (0.010 in) before TDC, the BMW MoDiTeC must display the correct ignition firing point. Installation is the reverse of the removal procedure. 00 2 510 KR120020 • • • Screw dial gauge, BMW No. 00 2 510, with extension, BMW No. 00 2 580, into cylinder No. 1.
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Replacing three-phase generator Removing and installing three-phase generator Disassembling the three-phase generator Removing and installing drive housing L Note: It is not necessary to remove the gearshift linkage, 2 2 gearbox and clutch slave cylinder. – a Raise the frame. ...................................................See Group 23, Removing gearbox KR120030 • 1 Take out rubber dampers (2). 4 KL120010 3 • • • Remove the three securing screws (1).
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Replacing starter motor Removing and installing voltage regulator Removing and installing starter motor – 1 a Remove gearbox complete with starter motor. ....................................................See Group 23 6 2 3 4 KR120130 • • Remove screws (2). Carefully open clips (1, 3, 4) and remove the housing cover. KL120080 • • 5 Remove screw (6) and remove the starter motor.
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10 6 2 3 4 7 8 9 5 1 11 KL120090 12 Disassembling/assembling starter motor • • Clamp the starter motor into a vise with soft jaws. Unscrew tie-rods (1). L Note: Align plastic retainer (6), brush holder (4) and inner insulator (3) with the stud (arrow) inside the housing. e Caution: • Before removing or installing the housing cover, always fit a length of shrinkable PVC tubing over the splines on the armature.
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12.
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13 13 Fuel preparation and control Contents Page Technical Data ............................................................................................................................... 3 Removing and installing Motronic control unit ...........................................................5 Replacing intake air filter element ......................................................................................5 See Group 00 ...................................................................
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13 Technical Data K 1200 LT Fuel grade Super (premium), unleaded, 95 octane (RON) Mixture preparation Motronic MA 2.4 Fuel pressure Throttle valve stub inside dia. bar (psi) 3.5 (49.80) mm (in) 34 (1.34) Air filter Multi-layer paper element Intake stub pipe With resonance damper Throttle cable play (engine warm) [without cruise-control system] mm (in) 0.5 (0.02) [with cruise-control system] Total play, throttle-opener and throttle-closer cables mm (in) 1 ... 1.5 (0.04 ... 0.
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Removing and installing Motronic control unit Replacing air temperature sensor – d a Warning: Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressurised. • a – a • • Remove left and right fairing side sections. ....................................................See Group 46 Remove front seat with bridge. ....................................................See Group 52 Remove fastener securing fuel tank to frame.
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Removing and installing intake air silencer 2 – a 3 4 5 Remove left and right fairing side sections. ....................................................See Group 46 d Warning: Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressurised. – a Remove fuel tank. ....................................................See Group 16 KL130070 • • • • • KR130240 • • Remove screw (arrow) securing suction pipe. Remove air outlet duct for left radiator.
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Removing and installing fuel injection rail – a • Remove left and right fairing side sections. ....................................................See Group 46 d Installation is the reverse of the removal procedure: pay particular attention to the following. L Note: Make sure that the O-ring at the injector is in good condition. Lightly oil the O-rings. Warning: Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressurised.
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Removing and installing pressure regulator – Remove left and right fairing side sections. d Warning: Comply with safety precautions when handling or working with fuel. Removing and installing throttle valve rail e Caution: Do not slacken the fasteners securing the throttle valve stubs to the throttle valve rail. – a – a • Remove fuel tank. ....................................................See Group 16 Use hose clamps, BMW No. 13 3 010, to close off fuel hoses at injection rail.
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1 2 8 5 4 3 6 KL130040 • • • • • • • Disconnect plug (4) for switch of cruise-control system. Disconnect the earth (ground) cable (3) from the throttle valve rail. Disconnect plug of throttle-valve potentiometer (2). Disconnect plug of throttle-valve actuator (1). [Activated charcoal filter] Disconnect breather hose to timing valve from y-piece. Slacken screws securing hose clips at intake stubs. Remove throttle-valve rail from intake stubs. • • • • KL130030 Remove circlip (8).
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Removing and installing throttle valve actuator Replacing and adjusting throttle valve potentiometer – – Remove left and right fairing side sections. Remove throttle valve rail. d Warning: Comply with safety precautions when handling or working with fuel. – a – Remove fuel tank. ....................................................See Group 16 Remove fuel injection rail. KR13016 • • 1 L Note: KL130100 • Disconnect plug of throttle valve actuator (arrow).
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Removing and installing intake stubs • Remove throttle valve rail. 2 1 KR130080 • KR130090 • Remove screws (arrows) and remove intake stubs complete with sealing rings. L Note: When installing the rear intake stub, do not forget Open clip (arrow) securing fuel-supply hose (1) and fuel-return hose (2). d Warning: Comply with safety precautions when handling or working with fuel. • Installation is the reverse of the removal procedure: pay particular attention to the following.
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Removing and installing throttle cables Removing and installing throttleopener and throttle-closer cables Preparatory work for all Bowden cables – – a – a – Remove left and right handlebar trim sections. ....................................................See Group 46 Remove cover of fork bridge. Remove left and right fairing side sections. ....................................................See Group 46 Remove tank cover.
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1 2 3 1 3 KL130010 • Installation is the reverse of the removal procedure: pay particular attention to the following. e Caution: Route Bowden cables so as to avoid tight bends 4 and make sure they are not kinked or pinched. • • • 5 KL130030 e Caution: Do not remove retaining plate (5): the screws locate the throttle valve stubs. • • Disengage throttle-closer cable (3) from its pull (2) at the throttle valve rail. Remove circlip (4) and remove throttle-closer cable.
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1 4 3 KL130010 2 Removing and installing Bowden cable of cruise-control system • • Carefully pull apart sleeve (4) and lower cable sheath (arrow) and remove insert (3). Disengage Bowden cable (2) from its pull at throttle-valve rail. 5 • Installation is the reverse of the removal procedure: pay particular attention to the following. e Caution: After installing, check that Bowden-cable pulls at throttle valve stubs move freely.
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Checking fuel pressure – a Removing and installing control unit of cruise-control system Remove right side section of fairing. ....................................................See Group 46 See Group 65 Checking throttle cable play, adjusting if necessary See Group 00 KL130110 d Warning: Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressurised. • • Connect a test pressure gauge, BMW No.
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13.
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16 16 Fuel tank and lines Contents Page Technical Data ............................................................................................................................... 3 Removing and installing fuel tank Renewing fuel filter .......................................................................................5 .....................................................................................................................6 Removing the fuel pump unit .............................
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16 Technical Data Tank capacity Motorcycle on side stand Motorcycle on main stand including reserve of Type of fuel K 1200 LT l (Imp. gal/ US gal) approx. 23.5 (5.17/6.21) l (Imp. gal/ US gal) approx. 22 (4.84/5.81) l (Imp. gal/ US gal) 4 (0.88/1.06) Super (premium), unleaded. 95 octane (RON) Fuel pump Type Operating voltage Fuel pressure Delivery volume peripheral-gear pump V 12 bar (psi) 3.5 (49.80) l/h (Imp. gal/h; US gal/h) 110 (24.21; 29.06) 16.
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1 KL160011 Removing and installing fuel tank L Note: The immersion-tube sensor has to be calibrated if it or the fuel tank has been replaced. e Caution: 13 3 010 Disconnect ground lead from battery and insulate. – – a • a d Warning: Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressurised. • • • 13 3 010 Remove left and right fairing side sections. Remove tank cover. ....................................................
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1 2 3 KL160020 Renewing fuel filter – Remove fuel tank. d Warning: Comply with safety precautions when handling or working with fuel. • Drain fuel tank. Removing the fuel pump unit • • Release union nut (3) using wrench, BMW No. 16 1 710. Remove fuel-pump unit (1) with seal (2). 16.
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Removing/installing fuel filter Removing/installing fuel pump • • • • • 1 2 • 14 4 • • 3 5 Detach connecting cables (1, 2) from fuel pump. Open hose clip (9) and disconnect hose (8). Release holder (13). Release vibration damper at pump outlet (14). Pull fuel pump (12) with pump inlet vibration damper (11) off holder (6). Pull pump inlet vibration damper (11) off fuel pump (12). If necessary, pry off intake filter (10).
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Removing/installing immersion-tube sensor Removing/installing roll-over valve – – a a Remove left and right fairing side panels. Remove tank cover. ....................................................See Group 46 – – • Remove left and right fairing side sections. Remove tank cover. ....................................................See Group 46 Disconnect the drain hose. e Caution: Disconnect ground lead from battery and insulate.
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17 17 Radiator Contents Page Technical Data ............................................................................................................................... 3 Coolant circuit ................................................................................................................................5 Removing and installing coolant hoses ...........................................................................7 Connecting hose between left and right radiators ...................
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17.
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17 Technical Data K 1200 LT Cooling system capacity Total capacity l (Imp. pints/ US quarts) 3.1 (5.46/3.28) Coolant circuit l (Imp. pints/ US quarts) 2.5 (4.40/2.64) Coolant expansion tank l (Imp. pints/ US quarts) 0.6 (1.06/0.63) Coolant Use only nitrite-free long-term antifreeze and corrosion inhibitor.
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17.
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Coolant circuit KL179000 17.
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17.
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1 2 3 6 5 Removing and installing coolant hoses – a Drain coolant. ....................................................See Group 00 Connecting hose between left and right radiators 4 KL170010 Coolant hose to water pump – • Remove right section of engine spoiler. Remove coolant hose (6) to oil/water pump. Removing breather hose d Warning: Comply with safety precautions when handling or working with fuel. – • Remove left and right fairing side sections.
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Changing coolant Removing and installing radiator with fan See Group 00 Removing and installing left radiator – a Checking cooling system for leaks – a Remove left and right fairing side sections. ....................................................See Group 46 d Warning: Comply with safety precautions when handling or working with fuel. – a – Remove fuel tank. ....................................................See Group 16 Open the filler cap on the left radiator.
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• Installation is the reverse of the removal procedure: pay particular attention to the following. KL170050 • Disconnect plug (arrow) for fan and remove air outlet duct. KL170040 L Note: Route Bowden cable (arrow) for cruise control system past the air outlet duct. Before installing the air outlet duct, pass the cable for the fan through the hole in the air outlet duct and connect the plug.
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Removing and installing right radiator – a – – a Remove left and right fairing side sections. ....................................................See Group 46 Remove centre and right sections of engine spoiler. Drain coolant. ....................................................See Group 00 • • Remove 2 screws (2) and remove air outlet duct. Disconnect fan plug. 4 d Warning: Comply with safety precautions when handling or working with fuel. – a • 5 Remove fuel tank. ................................
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Removing and installing coolant stub pipe on engine Removing and installing thermostat – – a – a Drain coolant. ....................................................See Group 00 Remove left engine cross-member. ....................................................See Group 46 a • Drain coolant. ....................................................See Group 00 Disconnect coolant hose from thermostat. 4 1 2 5 3 6 7 Kr170100 KL170030 • • • Slacken hose clamps (1, 2) and disconnect hoses (arrows).
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Troubleshooting Coolant overheat warning light comes on. Check coolant in expansion tank. Is coolant level too low? yes Add coolant. no Check thermostat. Thermostat does not open. Is the left radiator warmer than the right one, and the coolant pipe to the water pump hot? yes Replace thermostat. no Test the water pump. Is water pump faulty? yes Repair/replace water pump. Fan motor does not cut in. Check fuses. Fuse blown? yes Replace fuse. no Check fan relay.
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Excessive loss of coolant. Check coolant circuit. Coolant circuit is interrupted or leaking? yes Reconnect or repair leak, as applicable. Engine remains cold or warms up very slowly. Check thermostat. Thermostat does not close. Are both radiators equally warm and the coolant hose to the water pump cold? yes Replace thermostat. 17.
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17.
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18 18 Exhaust system Contents Page Technical Data ............................................................................................................................... 3 Removing and installing exhaust heat shield Removing and installing exhaust system Removing oxygen sensor ...............................................................5 ........................................................................5 ................................................................................
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18.
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18 Technical Data K 1200 LT Exhaust system Emission control 3-way catalytic converter Silencer (muffler) Reflection/absorption silencer, non-rusting stainless steel 18.
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18.
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Removing and installing exhaust heat shield Removing and installing exhaust system • – Slacken screws securing front left footrest plate. a Remove left-hand section of engine spoiler. ....................................................See Group 46 L Note: The bottom fastener of the rear footrest plate is secured to the battery bracket. When removing the battery cover, slacken but do not remove the screw. – – – 1 KL180010 • Slacken screws securing rear left footrest plate.
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• • • • • • • • KL180020 • • Remove eight screws (arrow) securing exhaust system to cylinder head. Extend side stand. L Note: Make sure the oxygen sensor clears the gearshift lever. • • Pull exhaust down to clear the stud and forward out of its holder. Lower the exhaust system to remove. Removing oxygen sensor 11 7 020 KR180100 • Unscrew the oxygen sensor at the hexagon (arrow). 18.6 Installation is the reverse of the removal procedure: pay particular attention to the following.
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21 21 Clutch Contents Page Technical Data ............................................................................................................................... 3 Removing and installing clutch Preparatory work ............................................................................................5 .............................................................................................................................5 Removing clutch ................................................
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21 Technical Data K 1200 LT Clutch Type Single dry plate clutch (asbestos-free) Operation Hydraulic Clutch fluid DOT 4 brake fluid Clutch plate dia. Wear limit: Minimum clutch plate thickness mm (in) 180 (7.02) mm (in) 4.6 (0.18) (measured with tips of calipers pressed by hand against rivets of clutch plate) 21.
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21.
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1 2 3 4 5 6 7 KL210011 Removing and installing clutch Removing clutch Preparatory work • • – – – – – – – – – – – – – – Remove fairing and engine spoiler. Remove the battery. Slacken exhaust system. Remove the inductive sensor on the rear wheel. Remove the rear wheel brake caliper, fasten to the rear frame with the inductive sensor using a cable tie. Remove rear wheel. Remove rear wheel drive unit. Remove the swinging arm. Remove cross tube. Remove clutch slave cylinder. Withdraw clutch pushrod.
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1 2 3 4 5 KL210020 Removing clutch housing • • • • • • 11 2 821 KR210030 • Secure the holder, BMW No. 11 2 821, as illustrated. 21.6 Unscrew hex nut (5). Remove thrust ring (4). Move clutch housing (2) backwards and forwards until the O-ring (3) is visible. Remove the O-ring (3). Pull off the clutch housing (2). Remove thrust washer (1).
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1 2 3 4 5 KL210020 Installing clutch housing • • • • Lightly oil the internal spline (2). Install thrust washer (1) between output shaft and intermediate flange; apply a blob of grease to hold the thrust washer in place, if necessary. Fit the clutch housing (2). e Caution: Fit new nuts (5). • • 2 • • 11 2 500 • 11 2 821 Fit the mounting fixture, BMW No. 11 2 821, on the clutch housing at the position illustrated. Fit a new O-ring (3) and thrust ring (4).
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1 2 3 4 5 6 7 KL210011 Installing clutch • Tighten screws (7) to hold clutch in position. e Caution: Always use new screws. • Grease all lubrication points with Optimoly MP 3. 21 2 672 Lubrication points: Splines on clutch plate and input shaft. Diaphragm spring contact surface on clutch housing. Diaphragm spring contact surface on pressure plate.
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Changing the clutch fluid/bleeding the clutch system L Note: This description applies for the brake filling and bleeding unit with extraction of the brake fluid by a partial vacuum at the brake caliper. If other devices are used, comply with their manufacturers’ instructions. – – Place the motorcycle on its centre stand so that it is level. Remove right fairing section skirt. e Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid attacks paint.
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• • e Caution: Pull the protective hose over the filling adapter. Secure the breather hose to the right skirt with a cable tie. Do not permit brake fluid level to drop below the MIN mark during the bleeding process, otherwise air will be drawn into the clutch system. Bleed the system again if this happens. • Draw off brake fluid until it emerges clear and free from air bubbles. e Caution: Dispose of old brake fluid in an environmentally friendly manner.
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2 1 3 KL210230 Removing and installing vent line • • • Unscrew the banjo bolt (1) on the clutch slave cylinder. Remove sealing rings (3) and vent line (2). Assembly is the reverse of the disassembly procedure: pay particular attention to the following. 4 e Caution: Route the vent line without kinks such that contact with the spring strut is not possible in any situation. Always use new sealing rings (3). • • • Fill clutch system with brake fluid. Bleed the clutch.
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1 2 3 4 Removing and installing clutch pressure line – – • • • • • • • • • Remove left side section of fairing. Remove fuel tank. Cut the cable ties on the injection rail and frame. Undo the junction in the clutch pipe (arrow). Unscrew the banjo bolt (5) on the clutch slave cylinder. Remove sealing rings (6). Remove pressure line (4), withdraw to the rear. Turn the clutch-lever fitting so that the securing screw (2) of the clutch line is accessible.
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Removing and installing clutch slave cylinder – a – – a – – – – a – • • Remove left fairing section, battery cover and engine spoiler. ....................................................See Group 46 Remove the right and left front and rear footrest plates. Remove the exhaust system ....................................................See Group 18 Remove the inductive sensor on the rear wheel. Remove the rear wheel brake caliper, fasten to the rear frame with the inductive sensor using a cable tie.
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Removing and installing clutch release rod – a – – a – – – – a – 9 Remove left fairing section, battery cover and engine spoiler. ....................................................See Group 46 Remove the right and left front and rear footrest plates. Remove the exhaust system ....................................................See Group 18 Remove the inductive sensor on the rear wheel. Remove the rear wheel brake caliper, fasten to the rear frame with the inductive sensor using a cable tie.
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23 23 Gearbox Contents Page Technical Data ............................................................................................................................... 3 Gearbox – sectional drawing ..................................................................................................5 Replacing the shaft sealing rings in the gearbox housing and gearbox cover .......................................................................................................................
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Contents Page Disassembling/assembling output shaft .............................................................................21 Disassembling output shaft ...............................................................................................................21 Assembling output shaft ....................................................................................................................22 Checking endplay ...........................................................................
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23 Technical Data K 1200 LT Type of gearbox 5-speed gearbox (4 + overdrive) with integral reverser, claw-action shift and reaction damper. Reverser actuation with lock-out mechanism for forward gears and electric safety elements, plus Hall-effect transmitter for reverser speed control by reverser control unit. Gear shift type By shift pedal and selector drum with overrun protection Reverser actuation By central selector shaft with actuation angle of approx. 42°.
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Gearbox – sectional drawing Design MT-1 BMW Grafik KL239000 23.
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23.
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23 4 771 23 4 731 23 4 772 23 4 732 23 4 712 23 4 711 KL230110 Replacing the shaft sealing rings in the gearbox housing and gearbox cover Replacing output shaft sealing ring L Note: immediately behind the shaft sealing ring: take care not to damage the sealing washer when removing the sealing ring. All shaft sealing rings can be replaced with the gearbox installed, apart from the input-side shaft sealing ring on the input shaft. Replace all shaft sealing rings if the gearbox is fully disassembled.
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23 4 721 23 4 722 00 8 581 00 8 582 00 8 583 23 4 750 23 4 740 23 4 612 KL230120 Replacing input shaft sealing ring at output side Replacing shaft sealing ring for selector drum • • • • Pierce the shaft sealing ring with awl, BMW No. 00 8 583. Screw the pull rod, BMW No. 00 8 581, into the hold and use impact weight, BMW No. 00 8 582, to remove the shaft sealing ring. Install the new sealing ring with the sealing lips facing inwards, using guide, BMW No. 23 4 722, and drift, BMW No. 23 4 721.
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8 6 7 5 1 2 3 4 KL230040 Removing and installing actuating unit for reverser Removing and installing actuating control for reverser • • • L Note: Install the actuating control (2) with the grip projection at the top. Make sure that all cables are correctly routed and are not pinched or kinked. Remove screw (1). Remove actuating control (2) for reverser. Clean threads of screw (1), coat with Loctite 243 and install.
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Disassembling/assembling double switch for reverse gear Removing gearbox e Caution: Disconnect the negative cable from the battery first, followed by the positive cable. 1 • • • • • • 2 3 KL230140 • • Turn actuating lever (3) clockwise until the flats (arrows) are toward contacts (1). Remove the actuating lever. • • • • • • • Disconnect the battery. Remove the left and right fairing side sections. Remove actuating control for reverser. Remove engine spoiler. Remove left and right skirt brackets.
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1 2 KL230010 • • • • • Remove exhaust system. Fit lifting gear, BMW No. 00 1 510. Remove rear wheel. Remove inductive sensor from rear wheel drive. Remove the rear wheel brake caliper, fasten to the rear frame with the inductive sensor using a cable tie. d Warning: Note high release torques. • • • • • • • Remove actuating unit for reverser, complete with switch unit. If the gearbox is to be fully disassembled, remove the main (centre) stand.
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5 4 6 3 2 1 7 8 9 KL230010 • • • • • • • Disconnect plug for speed sensor (5) of reverser at right-hand skirt bracket. Remove nuts securing cross member to engine at left and right. Remove the clutch slave cylinder (8). Remove clutch release rod (7) from the gearbox. Secure front wheel in position. Use workshop crane, BMW No. 46 5 640, to raise rear of frame high enough to take weight off gearbox mounts. Remove gearbox mounting bolt (6).
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2 3 1 4 10 5 9 8 7 6 KL230130 Disassembling gearbox Preparatory work • • • • • • • Remove screw (1) securing starter motor (2) and remove starter motor from gearbox housing. Remove oil filler/level check screw (5). Remove oil drain plug (6) and drain the oil from the gearbox into a suitable tray. Remove breather (3). Remove speed sensor for reverser (4). Remove selector lever (7). Remove nut (10) and remove actuating lever (9) with double switch (8) for reverse-gear indicator. 23.
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00 8 585 1 6 7 2 3 5 00 8 581 00 8 584 00 8 582 8 4 9 10 KL230150 Disassembling reverser gear train • Remove eight screws (1). L Note: 00 8 584 Note the original positions of each of the screws securing the cover of the reverser. 00 8 582 e Caution: Do not damage the 2 sleeves (cover (2) and gearbox housing). • • • • Use M6 adapter, BMW No. 00 8 585, and puller, BMW No. 00 8 580, to release cover (2) of reverser from gearbox housing and remove cover.
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00 8 581 1 2 3 00 8 582 00 8 585 4 5 6 KL230170 • • Use a screwdriver to pry out sealing ring (1) of actuating shaft. Remove circlip (2) from gearbox housing. e Caution: When removing, make sure that retaining ring (4) for pawl (5) and driver (6) does not drop into the gearbox housing. • • • • • Remove circlip (4) from actuating shaft. Turn actuating shaft so that pawl does not engage selector drum. Using an M6 adapter, BMW No. 00 8 585, and puller, BMW No.
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1 2 23 4 780 3 Removing gearbox housing 23 4 780 L Note: Do not drive back centring pins (2, 3). • w KL230180 80…100 h Remove the nine screws (1) securing the cover to the housing. 23 4 700 KL230100 • • Insert gearbox into mount, BMW No. 23 4 700. Secure press-off tool, BMW No. 23 4 780, to mount of clutch slave cylinder. e Avoid damage to the housing cover and painted surfaces. • • 23.16 Heat the bearing points in the housing to 80 °C... 100 °C (176 °F...212 °F). Use press-off tool, BMW No.
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1 1 9 2 3 4 8 5 7 6 Removing selector drum • • • • • • • • • Pull the selector shafts (1) out of the selector forks. Swing selector forks (2, 8, 9) out towards the edge of the cover. Remove locking pin (5). Press guide plate (4) in the opposite direction to the spring loading (arrow). Swing locking lever (6) out towards the edge of the cover, hold it there and pull out selector drum (7), turning it slightly at the same time. Remove the thrust washers and spacing washer.
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1 3 2 80…100 h w KL230300 Removing gearbox shafts • • Heat bearing points in gearbox cover to 80 °C … 100 °C (176 °F ... 212 °F). Remove input shaft (2), output shaft (3) and intermediate shaft (1) from the cover together. 00 7 500 Replacing grooved ball bearing on intermediate shaft e Caution: Apart from the grooved ball bearings, the intermediate shaft must always be replaced as a complete unit. If the grooved ball bearings are replaced, the fully assembled length must be re-adjusted.
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1 2 3 4 5 11 6 7 8 9 10 KR230081 Disassembling/assembling input shaft Disassembling input shaft • • • • • 00 7 500 Remove guide ring (7). Compress spring cluster (4) and remove split segment washer (6). Remove backup washer (5), spring cluster (4), anti-rattle disc (3), thrust block (2) and constantspeed gear (1). Clamp input shaft (10) other way round in vise. Use universal puller, BMW No. 00 7 500, and pressure head (arrow) to pull off grooved ball bearing (11).
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1 2 3 4 5 11 6 7 8 9 10 KR230081 Assembling input shaft • Lightly oil the bearing surface for constant-speed gear (1) on input shaft (10), and install the constant-speed gear. • Lightly oil the splines in thrust block (2) and install it. • Place anti-rattle disc (3) on thrust block (2). • Mount spring cluster (4) with locating ring (arrow) facing upwards on anti-rattle disc (3). • Install backup washer (5) of the same thickness as the original washer.
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1 2 3 4 5 14 13 12 6 11 10 9 8 7 15 16 17 18 19 KL230210 Disassembling/assembling output shaft Disassembling output shaft • • • e Caution: To avoid damaging the needle roller bearing on the • • splines, spread the rollers carefully at the end face when removing. • • • Remove needle roller bearing (16). Remove the sliding gearwheel for 4th gear (7). Remove circlip (8), backup washer (9), shift gearwheel for 3rd gear (10) and needle roller bearing (11). Remove 5th stage spur gear (12) of reverser.
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15 16 17 18 19 13 12 11 10 9 8 7 6 1 2 4 3 5 14 KL230220 e Caution: Assembling output shaft L Note: Begin by installing 5th stage spur gear (12) of reverser. Before assembly, oil all friction faces lightly with gear oil. To avoid damaging the needle roller bearing on the splines when installing, spread the rollers carefully at the end face. • • • • • 6 • • 13 • • KR230130 – a • • Clamp the output shaft into the vise with soft jaws and with the splined end up. Install circlip (13/arrow).
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40 50 60 30 70 20 80 10 6 0 KL230230 • • • • • a • • Reverse position of output shaft (6) in vise. Install sliding gearwheel for 5th gear (14) with the recess for the selector fork facing the 2nd gear shift wheel (4). Install backup washer (5) and needle roller bearing (3). Install the shift wheel for 2nd gear (4) with the dogs facing the 5th gear sliding gearwheel (14). Check/adjust fully-compressed length. .........................................................
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30 40 60 70 50 80 40 60 60 70 50 80 50 80 70 20 10 90 30 0 20 10 0 90 0.2 40 90 30 0 20 10 23 4 762 C 1 23 4 765 23 4 763 A B 23 4 761 1 3 2 Checking/adjusting fully assembled length of gearbox shafts Checking/adjusting fully assembled length of intermediate shaft KL230250 • Using the dial gauge, measure the deviation from zero of distance “B” at the inner bearing race. Deviation from zero is equivalent to the thickness “C” of spacer (1).
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10 20 30 90 30 50 60 70 60 70 50 80 40 40 90 80 50 60 70 0 0 30 40 90 0.2 80 20 10 20 0 10 23 4 762 1 C 23 4 766 23 4 763 A B 23 4 761 1 Checking/adjusting fully assembled length of output shaft e Caution: Check and adjust the fully assembled length as described below and install a spacing washer of the correct thickness. Before measuring, always make sure that the grooved ball bearings are pressed fully home, even if the shaft has not been disassembled and reassembled.
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20 10 30 90 30 50 60 70 60 70 50 80 40 40 90 80 50 60 70 0 0 30 40 90 0.2 80 20 10 20 0 10 23 4 762 1 C 23 4 764 23 4 763 A B 23 4 761 23 4 767 1 Checking/adjusting fully assembled length of input shaft e Caution: Check and adjust the fully assembled length as described below and install a spacing washer of the correct thickness.
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A KR230190 Checking/adjusting fully assembled length of selector drum • • • Place spacing washer and both thrust washers on the selector drum. Using slide gauge, determine fully assembled length “A”. If necessary, adjust fully assembled length “A” with a shim (arrow). Fully assembled length: Selector drum ...... 111.80 … 111.90 mm (4.402 … 4.406 in) 23.
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Shimming selector shaft C e Caution: If the housing or the complete selector shaft is replaced, the selector shaft must be measured and shimmed. KL230380 A • • KR230200 • Measure distance “A” from shouldered bushing to cover mating face. B KR230210 • Measure distance “B” from shouldered bushing to housing mating face. 23.28 Measure distance “C” from the shoulder on the selector shaft to the back of the sleeve.
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1 3 2 23 4 712 80…100 h w KL230300 Assembling gearbox Installing selector shaft Installing gearbox shafts Installing input, output and intermediate shafts e Caution: Before installing, the gearbox shafts, housing and cover must be thoroughly cleaned and examined for damage. Replace all shaft sealing rings. Check that the gearbox shafts are correctly seated. • • • • • • Insert the cover into gearbox mount, BMW No. 23 4 700.
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1 1 9 2 3 4 8 5 7 6 Installing selector drum • • • • • • • Place a spacing washer of the correct thickness and the input-side thrust washer on selector drum (7) and secure with a small amount of grease. Swing locking lever (6) out towards the edge of the cover and install the selector drum. Swing locking lever (6) towards selector drum (7) and engage it in position together with guide plate (4). Place shift forks (2, 8, 9) in the guides. Install selector shafts (1). Install locking pin (5).
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23 4 732 23 4 712 23 4 612 KL230310 • w Installing gearbox housing Install pin (arrow) in cover. 80…100 h e Caution: Clean and de-grease the sealing faces. The sealing compound sets within 30 minutes; within this time, place the housing in position and tighten the securing screws. • • • • Using the metering device, apply Loctite 574 surface sealant to the mating face of the cover. Place assembly sleeve, BMW No. 23 4 732, on the output shaft. Place assembly sleeve, BMW No.
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2 3 4 1 KL230290 L Note: Installing reverser – Select neutral. Always use a new circlip (2). 3 2 • 4 – Introduce actuating shaft into gearbox housing and slip pawl (3) with long lug toward collar and driver (4) with flat toward 5th stage spur gear onto actuating shaft. The pawl must be able to engage the selector drum. e Caution: When reassembling, take care not to drop the circlip into the gearbox and make sure that the circlip is correctly seated in its groove. KL230330 23.
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1 00 8 581 2 3 5 4 12 11 00 8 584 8 9 23 4 772 10 23 4 771 7 6 KL230151 • Fit a new retaining ring (6) in groove in housing bore. e Caution: Endplay of actuating shaft must be perceptible be- • • • fore sealing ring (7) is installed. • • • • Use slip-over sleeve, BMW No. 23 4 771, and drift, BMW No. 23 4 772, to install new sealing ring (7). Working from above, insert 3rd stage spur gear (3). Install bearing pin (9). Using adapter, BMW No. 00 8 584, and pull rod, BMW No.
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1 2 3 5 12 11 8 4 9 10 7 6 KL230151 Performing a functional check • Mount shift lever on selector shaft and engage neutral. • Mount actuating control on actuating shaft of reverser. – It must be possible to engage the reverser with the gearbox in neutral. If necessary, turn the output shaft to move the gears slightly. If it does not engage, remove reverser and reinstall. • Remove actuating control for reverser.
PAGE 237
1 2 3 KL230340 4 e Caution: 5 When installing the reverse gear switch, make sure that the rear retaining plate does not slip between gearbox housing and actuating lever. Actuating lever (2) must be seated against shaft collar. • Install new stop nut (1) and tighten. X Tightening torque: Reverse gear switch on actuating shaft.......... 9 Nm 2 6 KL230140 Install actuator unit for reverser • Install actuating lever (2) in holder (4) with the flats (arrows) toward contacts (5).
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1 2 3 4 6 5 KL230350 Completing assembly of gearbox 6 e Caution: Make sure that breather (1) is correctly seated in groove in bore. • Press breather (1) home in bore. e Caution: Clean metal particles off the magnet in drain plug (5). • • • • • Install oil drain plug (5). Insert oil inspection plug (4) with a new sealing ring. Check O-ring of speed sensor (2) for damage, replace if necessary. Install speed sensor (2). Install gear indicator switch (3).
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5 6 4 3 7 2 1 KL230010 Installing gearbox L Note: 23 1 821 Always install new engine-side and gearbox-side sealing rings for starter motor. Use one hand to press the starter motor profiled sealing ring on the gearbox side into its groove. • • 23 1 822 Install sealing rings. Introduce starter motor (5) into bore in crankcase. L Note: KL210041 If not removed, the main (centre) stand must be retracted to permit installation of the gearbox. • • • Secure guide pins, BMW No.
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5 6 4 3 7 2 1 KL230010 L Note: • • • • • Apply Loctite 243 to threads of screw (3). • • Position link (4) for reverser against gearbox housing. Install screw (3) with threads coated with Loctite 243. Tighten all seven screws securing gearbox to intermediate flange. e Caution: To prevent the clutch slave cylinder from tilting, tighten three securing screws alternately and uniformly. • • • • • • Install clutch release rod.
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• • • • • • • • • • • • • • • • • • • • • • • • • Fully lower the frame. Remove workshop crane, BMW No. 46 5 640. Install skirt brackets. Connect plugs for oxygen sensor, side-stand switch, and coolant-temperature sensor. Install actuating unit for reverser, complete with switch unit. Install radiators with fans left and right in holders. Reconnect plugs and cables for engine and gearbox. Install transverse tube. Install front drive shaft. Install swinging arm. Install rear wheel drive.
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2 1 3 4 5 10 6 7 8 9 KL230030 Removing and installing gearshift lever and linkage Removing and installing gearshift lever • • • • • • • • • • • • • Slacken screws securing front footrest plate. Remove retainer pin (2). Disengage gearshift linkage at ball joint (1). Remove front footrest plate. Remove bearing screw (8). Remove retaining pin (5). Disengage gearshift linkage at ball joint (6). Remove relay lever (3). Remove selector lever (7).
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2 3 1 KL230050 Aligning rubber mounts • Aligning left-hand rubber mount e Caution: The alignment of the left-hand rubber mounts relative to the frame is preset at the factory. Do not slacken the paint-marked Torx screws (1) unless the rubber mount has to be replaced. Lightly press bearing bushing against template and uniformly tighten screws (1).
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23.
PAGE 245
31 31 Front fork Contents Page Technical Data ............................................................................................................................... 3 Removing and installing telescopic forks and fork bridge ...................................5 Removing telescopic fork ............................................................................................................5 Removing fork bridge ...............................................................................
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Installing left angular-contact ball bearing for leading link Installing leading link ...................................................................................................................22 Measuring the leading link 31.2 .........................................21 ....................................................................................................
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31 Technical Data K 1200 LT Front suspension Type Telelever with anti-dive, leading link pivoted centrally on main frame. Fixed telescopic fork tube Fixed fork tube surface Hard chrome plated Fixed tube external dia. mm (in) 35 (1.38) Maximum permissible fixed fork tube runout mm (in) 0.4 (0.016) Telescopic fork oil Telescopic fork oil – approved grades Capacity per fork leg, SHOWA BMW telescopic fork oil, SHOWA ATF l (Imp. pints/ US quarts) 0.47 (0.827/0.
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31.
PAGE 249
Removing and installing telescopic forks and fork bridge – – a – 1 Remove left and right fairing side sections, tank cover and engine spoiler. Remove cover of fork bridge. ....................................................See Group 46 Attach hoist, BMW No. 00 1 510, to oil sump. Removing telescopic fork e Caution: Do not operate the handbrake lever when the brake calipers have been removed. Protect painted parts from scratching: apply adhesive masking tape if necessary.
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3 2 31 5 600 4 1 w w 5 KR340200 KL310111 e Caution: e Caution: Screws (1, 2) for retaining plates (5, 4) are secured with thread-locking compound. Carefully heat screws (1, 2); do not damage socket head when removing. Screw is secured with thread-locking compound; heat to max. 120 °C (248 °F) if necessary. • • • Remove screw (1) from holder (5) securing left brake line to telescopic fork. Remove screw (3) securing brake distributor for right brake line at holder (4).
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Removing fork bridge e Caution: Do not operate the handbrake lever when the brake calipers have been removed. Protect painted parts from scratching: apply adhesive masking tape if necessary. 1 • • • Remove screw (1) securing handlebar to fork bridge. Remove protective caps (arrow). Use spanner to hold fixed tube at w/f 22 flats and remove 2 nuts (2) securing fixed tubes in fork bridge.
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Disassembling fork bridge Removing angular-contact ball bearing with stud Removing and installing pot-type joints h 100 w 31 5 661 4 3 5 31 5 662 31 5 651 2 1 • • • KL310140 KL310120 Remove wiper (1). Remove snap ring (2). Press out pot-type joint (3) with wiper (4) using mandrel, BMW No. 31 5 661, and bushing, BMW No. 31 5 662. 1 2 31 5 661 wiper (1) if necessary. Install wiper (4). Press in pot-type joint (3) with mandrel, BMW No. 31 5 661. Install snap ring (2). Install wiper (1). 31.
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Installing fork bridge Removing stud • Installation is the reverse of the removal procedure: pay particular attention to the following. . 31 5 651 31 5 600 KL310051 L Note: Do not damage thread (arrow). • KL310040 e Caution: Press out stud with mandrel, BMW No. 31 5 651. When installing, always use new micro-encapsulated nut. Installing stud • L Note: Always install a new bearing. Tighten fastener securing fork bridge to frame with socket and adapter for socket-head screw, BMW No. 31 5 600.
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Installing telescopic fork 31 5 600 KL310110 e Caution: When installing, always use new micro-encapsulated nut. • Tighten fastener securing leading link to the fork slider tube bridge, using socket wrench insert and adapter for socket-head screw, BMW No. 31 5 600. e Caution: Preinstall telescopic forks, make sure they are under no strain and tighten fasteners to specified torques. • 1 • Insert left and right fixed fork tubes (2) into fork bridge (1). Compress the telescopic fork.
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• From this point on, installation is the reverse of the removal procedure: pay particular attention to the following. e Caution: When installing holder for brake line, use new screws or clean threads and coat with Loctite 243. • • Tighten screws securing holders for brake lines. Check that the system moves freely by compressing/extending the suspension in the straight-ahead position and with the steering turned to the full lock positions.
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X Assembly specification for telescopic fork Tightening torque: Bridge to slider tube (clean thread + Loctite 243).......................... 21 Nm e Caution: To ensure that the fork is installed without trapped • stresses, observe the following instructions and the specified working sequence precisely. • The front suspension strut is removed. e Caution: Protect painted parts from scratching: apply adhesive masking tape if necessary.
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Disassembling/assembling telescopic fork leg – • • Remove telescopic fork. Disassembling telescopic fork leg • • • • • Remove bleed screw (2). Remove oil drain plug (7) and drain oil into suitable container. Pull out fixed tube. Lever out the wiper (3). Remove retaining ring (4). Lever out shaft seal (5). Remove washer (6). Assembling telescopic fork leg 1 • 2 Remove oil under wiper (3). L Note: Traces of oil might indicate a leak. 3 • • 4 Oil capacity of each fixed fork tube ..........0.
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Measuring telescopic fork e Caution: After an accident, always examine the telescopic fork for cracks and signs of damage. Examining slider tube bridge and fork bridge • Check slider tube bridge and fork bridge for surface irregularities. e Caution: Replace slider tube bridge/fork bridge if deformed. Checking runout of fixed tube 00 2 510 KL310030 • • Place both ends of fixed tube in V-blocks. Turn fixed tube slowly and measure it with a dial gauge, BMW No. 00 2 510.
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Removing and installing slider tube bridge – a – Remove left and right fairing side sections and engine spoiler. ....................................................See Group 46 Attach hoist, BMW No. 00 1 510, to oil sump. e Caution: Make sure that brake line and front ABS sensor cable are not stretched when telescopic fork extends. Support the slider tubes. e Caution: Do not operate the handbrake lever when the brake 31 5 600 calipers have been removed.
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• Installation is the reverse of the removal procedure: pay particular attention to the following. Removing and installing ball joint L Note: Fixed tubes must be installed in fork bridge. • • 31 5 630 Preinstall quick-release axle in sliding tubes. Install screws securing fork slider tube bridge, but do not fully tighten. 1 e Caution: When installing, clean threads, use new nut or coat threads with Loctite 2701.
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Removing and installing front suspension strut Removing front suspension strut – – – – a 31 5 603 Remove engine spoiler. Remove fairing side section. Remove upper section of fairing. Remove cover of fork bridge. ....................................................See Group 46 31 5 601 KL310111 1 2 3 5 e Caution: Fastener securing leading link to slider tube fork bridge is secured with thread-locking compound; heat to max. 120°C (248°F) if necessary. 4 • KL310080 • • • • Secure hoist, BMW No.
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31 5 600 1 KL310080 • Turn suspension strut through 90°C and pull down, remove rubber ring (1). KL310280 • • 2 • • • • Clean threads of fasteners securing leading link to slider tube fork bridge and steering damper to leading link. Coat thread with Loctite 2701 and tighten fastener securing leading link to slider tube fork bridge with socket and adapter for socket-head screw, BMW No. 36 5 500. Coat thread with Loctite 243 and tighten fastener securing steering damper to leading link.
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2 1 KL310230 Removing and installing steering damper – a – a Remove front and rear sections of the front mudguard. ....................................................See Group 46 Remove front wheel. ....................................................See Group 36 e Caution: Fastener (1) securing steering damper to slider tube fork bridge (Torx) is secured with thread-locking compound. • • • Remove fastener securing steering damper to slider tube fork bridge. Remove steering damper.
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Removing and installing leading link Removing leading link • e Caution: Always replace the ball thrust bearing and the grooved ball bearing together. Disconnect ground lead from battery and insulate. e Caution: Comply with safety regulations; fuel lines are pressurised. – – a – a • • • • Remove fairing side sections. Remove engine spoiler. ....................................................See Group 46 Remove fuel tank. ....................................................
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Removing left angular-contact ball bearing for leading link Installing left angular-contact ball bearing for leading link • • • • Press the spacing sleeve fully into the angularcontact ball bearing. Cool the spacing sleeve with angular-contact ball bearing down to at least -10 °C (14 °F). Heat the frame at the left pivot bearing seat to approx. 100 °C (212 °F). Coat outer circumference of angular-contact ball bearing with assembly grease. 31 5 696 – • • • • • • • Remove the leading link.
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Installing leading link 1 2 • 4 3 5 Install angular-contact ball bearing and clamping sleeve in frame, using M 12 threaded rod, BMW No. 31 5 691, M 12 nut with mount, BMW No. 31 5 692, and puller sleeve, BMW No. 31 5 697; by screwing the M 12 threaded rod into the leading link from the left. L Note: Pull clamping sleeve and spacing sleeve together until gap is closed (arrow). • Tighten fastener (5) securing pivot of leading link to frame.
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– a – a – Install engine spoiler. ....................................................See Group 46 Install the fuel tank. ....................................................See Group 16 Connect earth (ground) strap to battery. Install fairing. e Caution: Make sure that brake line and front sensor cable are not stretched when telescopic fork extends. – Extend the telescopic fork. X Tightening torques: Leading link to frame (clean thread + Loctite 243)........................
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31.
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32 32 Steering Contents Page Technical Data ............................................................................................................................... 3 Removing and installing left grip tube ..............................................................................5 Removing and installing right grip tube ...........................................................................6 Removing and installing clutch lever fitting ................................................
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32.
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32 Technical Data K 1200 LT Type One-part jacketed tubular handlebar; without weights Handlebar diameter, inner tube mm (in) 22 (0.87) Handlebar diameter, outer tube mm (in) 28 (1.10) Steering lock angle Handlebar width with grip tube ° 32 mm (in) 826 (32.52) 32.
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32.
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3 4 1 2 KL320050 Removing and installing left grip tube – a – – – • • • • • • [With heated grip] Remove left and right fairing side sections. ....................................................See Group 46 [With heated grip] Remove tank cover. [With heated grip] Remove handlebar trim. [With heated grip] Remove fork bridge cover. [With heated grip] Disconnect plug (4) for the heated grip. [With heated grip] Pull cable shoe (3) out of connector. Remove fasteners (1) for grip.
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1 2 7 6 5 9 8 4 3 KL320041 Removing and installing right grip tube – a – – – • • • • • • • • • • [With heated grip] Remove left and right fairing side sections. ....................................................See Group 46 [With heated grip] Remove tank cover. [With heated grip] Remove handlebar trim. [With heated grip] Remove fork bridge cover. [With heated grip] Disconnect plug (9) for the heated grip. [With heated grip] Pull cable shoe (8) out of connector.
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2 3 4 5 6 1 7 8 9 17 10 16 13 12 14 11 15 KL320050 Removing and installing clutch lever fitting – – – – Remove left and right fairing side sections. Remove tank cover. Remove handlebar trim. Remove cover of fork bridge. e Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid attacks paint. • • • • • • • • • Drain the clutch operating system. Disconnect clutch line (4) from clutch-lever fitting.
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2 1 3 7 4 6 8 10 9 5 11 KL320040 Removing and installing brake lever fitting – a – – – Remove left and right fairing side sections. ....................................................See Group 46 Remove tank cover. Remove handlebar trim. Remove cover of fork bridge. e Caution: Do not allow brake fluid to come into contact with • • • • • • • • painted parts of the motorcycle, because brake fluid attacks paint. • • • • • • • • Drain fluid from brake system.
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Removing and installing handlebar – a – – – • • • Remove left and right fairing side sections. ....................................................See Group 46 Remove tank cover. Remove handlebar trim. Remove cover of fork bridge. Remove cable ties from handlebar. Remove left grip. Remove right grip. KL320110 1 e Caution: Make sure lines and Bowden cables are routed correctly; secure lines with cable ties (arrows). • a Check throttle cable play, adjust if necessary. .................................
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L Note: Use w/f 5 Allen key as gauge for adjusting. • Set distance “A”. Setting: Distance “A” ..................................... 5 mm (0.20 in) • Slightly tighten clamping screws. Handlebar: adjusting height KL320110 e Caution: B Make sure lines and Bowden cables are routed correctly; secure lines with cable ties (arrows). • Adjust handlebar in compliance with installation instructions.
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Removing and installing piston in brake-lever fitting • • e Caution: Do not allow brake fluid to come into contact with • Remove pivot screw (3) and remove lever. Clean threads of adjusting screw and pivot screw and threads in tapped bores of brakelever fitting. Remove rubber diaphragm from brake-lever fitting. painted parts of the motorcycle, because brake fluid attacks paint. • • • Remove right handlebar cover. Remove multi-function switch. Turn the handlebar fully to the left.
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Adjusting lever play for front brake/ clutch Front brake – Remove lower plastic cover from brake-lever fitting. – Remove cover for throttle-cable relay. • Complete assembly of handlebar fitting. X Tightening torques: Pivot screw (clean thread + Loctite 2701)........................ 11 Nm Removing and installing left and right handlebar levers e Caution: Pivot screw (3) is secured with thread-locking compound.
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33 33 Rear wheel drive Contents Page Technical Data ............................................................................................................................... 3 Rear wheel drive – cutaway drawing .................................................................................5 Removing, disassembling, reassembling and installing rear wheel drive ..............................................................................................7 Removing rear wheel drive .............
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Installing drive shaft .....................................................................................................................22 Installing rear swinging arm ......................................................................................................23 Removing and installing suspension strut 33.2 .........................................................................
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33 Technical Data K 1200 LT Rear wheel drive Gear tooth pattern Klingelnberg-Palloid spiral bevel Gear ratio 2.75 : 1 Number of teeth 33 : 12 Backlash mm (in) 0.07...0.016 (0.003...0.0006) Taper roller bearing preload mm (in) 0.05...0.1 (0.002...0.004) Oil grades Capacity Initial filling Oil changes Hypoid gear oil, SAE 90 API-GL-5 cc (fl. oz.) 240...250 (8.11...8.45) cc (fl. oz.) 230 (7.
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33.
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Rear wheel drive – cutaway drawing KL339000 33.
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33.
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Removing, disassembling, reassembling and installing rear wheel drive – a – a – a – – a Remove rear wheel. ....................................................See Group 36 Remove the inductive signal transmitter. ....................................................See Group 61 Remove the brake caliper. ....................................................See Group 34 Remove the rear wheel brake caliper and, fasten to the rear frame with the inductive sensor using a cable tie. Remove brake disc. ........
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Replacing taper roller bearing in rear wheel drive 4 e Caution: Do not damage the mating faces on the housing. w 00 8 573 j 120 KR330390 00 8 572 L Note: 1 Note circlip (4) at rear drive shaft. • Replace circlip (4) if necessary. KL330030 • Pull out needle roller bearing (1) with reaction support, BMW No. 00 8 572, and internal puller, BMW No. 00 8 573. 6 5 L Note: 7 Use temperature measuring device, BMW No. 00 1 900, to check heat rise. • • Heat neck of housing to 120 °C (248 °F).
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1 8 7 2 3 4 5 6 KL330050 e Caution: L Note: Never use a hammer when slackening off hex nut (5), or else the splines may be damaged. Use temperature measuring device, BMW No. 00 1 900, to check heat rise. d Warning: Hex nut (5) requires a high torque to loosen it. • Heat hex nut (5) on the input bevel pinion (6) to 100 °C (212 °F) and unscrew with a 36 mm (1.4 in) socket wrench insert and reducing adapter, BMW No. 33 1 720. d Warning: Threaded ring (3) requires a high torque to loosen it.
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Disassembling input bevel pinion 1 w j 120 00 7 500 33 1 510 KR330070 • Position rear wheel drive with retaining fixture, BMW No. 33 1 510, upright. • e Caution: To prevent the input bevel pinion (1) from being damaged if it falls out, use a soft underlay. • • KR330100 • Clamp input bevel pinion (1) into vise with protective jaws (splines facing upwards). Using puller, BMW No. 00 7 500, pull off both bearings at the same time. Heat bearing seat to 120 °C (248 °F).
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Removing needle roller bearing for input bevel pinion • Heat the housing to 100 °C (212 °F). Assembling input bevel pinion 1 2 00 8 575 00 8 573 3 00 8 570 4 5 KR330130 LT 33.006 KR330120 • Pull out the outer race of the needle roller bearing using internal puller, BMW No. 00 8 573, extension, BMW No. 00 8 575, and reaction support, BMW No. 00 8 570. w Installing needle roller bearing for input bevel pinion 100 h L Note: Clean the threads of the input bevel pinion prior to assembly.
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Installing input bevel pinion L Note: Clean the threads in the housing neck prior to as- 2 1 sembly. 1 2 33 1 510 3 4 j 120 w KR330160 • • • • 5 KL330070 Insert input bevel pinion (1) into housing. Install housing cover (5). Tighten fasteners (4) in diagonally opposite sequence. X Tightening torques: Housing cover to housing ............................ 35 Nm Secure the housing centrally in holder, BMW No. 33 1 510, using bearing stud (3).
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• • 1 33 1 720 e Caution: 33 1 700 • KL330060 • Clean the threads of hex nut (5). Coat the thread of hex nut (5) with Loctite 270. Attach locking arm (1). Make sure that the nut does not damage the shaft sealing ring. Keep thread-locking compound well clear of splined shaft: wipe off all deposits immediately. Tighten hex nut (5) with 36 mm (1.4 in) socket wrench insert and reducing adapter, BMW No. 33 1 720. X Tightening torques: Threaded ring (clean thread + Hylomar SQ 32) .................
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h w 80 3 4 2 5 1 6 7 KR330170 Removing crown wheel – • • • Remove housing cover (2). Remove shim (1). Heat housing cover (2) to max. 80 °C (176 °F) and remove from crown wheel (5). Drive shaft sealing ring (3) from the inside out of housing cover (2) with a suitable drift. 00 7 500 33 1 830 7 33 1 307 4 5 • • KR330180 • • • Clamp crown wheel (5) into vise with soft jaws. Insert thrust block (arrow), BMW No. 33 1 307. Using puller, BMW No. 33 1 830, pull off grooved ball bearing (4). 33.
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L Note: If new parts are installed (e.g. taper roller bearing), 00 8 560 check tooth backlash and adjust if necessary. 2 3 4 5 80 w h KR330200 • w h 80 Pull out the outer race using internal puller, BMW No. 00 8 560. Installing crown wheel KR330220 • 00 5 500 • 23 4 670 1 w 80 • • Affix original shim washer (4) to crown wheel (3) with grease. Heat taper roller bearing (5) to 80 °C (176 °F) and push it on. Install crown wheel (3).
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Checking/adjusting backlash 33 2 604 1 33 2 600 2 00 2 510 5 3 4 KR330220 KR330230 • • Position measuring fixture (3), BMW No. 33 2 600, with dial gauge, BMW No. 00 2 510, on crown wheel (4) and secure to housing by means of screw (1). Secure measuring arm (2), BMW No. 33 2 604, centrally to crown wheel (4). 90° 4 KR330240 L Note: Check tooth backlash at three points 120 degrees apart; turn the bevel pinion with the crown wheel.
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Checking tooth contact pattern 1 KR330270 KL330080 L Note: The tooth contact pattern must be checked if the gear set, housing or input bevel pinion bearing has been replaced. The contact pattern is adjusted by means of the shim washer (1) on the input bevel pinion. • • • L Note: The contact point is central on front flank V. The contact point is closer to the larger diameter on back flank R. – Install a thinner shim if the contact pattern looks like this. Use measuring fixture, BMW No.
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Shimming housing cover • Installing housing cover In order to obtain the correct taper roller bearing preload, the housing cover must be correctly shimmed. 00 5 500 33 1 860 1 h w 60 KR330310 a KR330290 • Using depth gauge, measure distance “a”. • • Lightly oil the shaft sealing ring (1). Using drift, BMW No. 33 1 860, and handle, BMW No. 00 5 500, drive in shaft sealing ring (1). e Caution: Do not overheat shaft sealing ring and cordring seal.
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Installing rear wheel drive 7 1 8 KL330020 KR330030 • Coat splines of rear universal shaft (1) with Optimoly MP 3. e Caution: Make sure that the inner race never presses against the ends of the needles. • • • Install the inner races (arrows) of the left and right needle roller bearings with a small quantity of grease. Push the flexible gaiter on to the neck of the housing and secure it with the clamping strap.
PAGE 300
1 2 3 5 4 6 7 8 9 KR330330 Removing, disassembling, reassembling and installing rear swinging arm e Caution: Removing rear swinging arm • • • • • – a – a – a – a – a – a – – a Remove the right and left front and rear footrest plates. ....................................................See Group 46 Remove left trim panel and battery cover. ....................................................See Group 46 Remove exhaust system. ....................................................
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Removing and installing flexible gaiter Removing and installing threaded ring bearings 33 6 644 1 KR330340 KR330700 • • Take out the inner circlip (arrow) and pull the flexible gaiter (1) out of the swinging arm. When installing, coat inner and outer sealing lips (arrows) with Staburags NBU 30 PTM. Removing bearing from left/right threaded ring • Engage pins (arrows) of press-out tool, BMW No. 33 6 644, in bores of threaded ring. • Press the left/right bearing out of the threaded ring.
PAGE 302
Removing drive shaft Installing drive shaft • • • 1 KR330350 • Use a tyre lever or similar tool to press off the front drive shaft (1). e Caution: Do not scratch painted components: if necessary, use a rubber mat. L Note: If necessary, remove/install the circlip in the joint element. Checking universal joint for wear KR330360 • – Determine endplay and radial play (arrows). Make sure that no play is perceptible at universal joint. 33.22 Coat the output shaft splines with Optimoly MP 3.
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1 2 3 4 KR330330 Installing rear swinging arm • • • Slide swinging arm over drive shaft and push forward as far as possible until rubber gaiter clicks into place on housing neck. Screw in left/right bearing studs (1, 4). Tighten screws (2, 3) securing suspension strut to swinging arm. 33 6 643 KL330090 • Using socket wrench insert, BMW No. 33 6 643, tighten bearing studs (1, 4) on left and right. 33.
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1 2 3 4 5 KR330330 • a 33 6 642 • a • a • a • a 33 6 641 • a • KL330100 • • • • Tighten the right threaded ring (4). Tighten the left threaded ring (3). Hold left threaded ring (3) with socket wrench, BMW No. 33 5 642, to prevent it turning and tighten locking ring (2) with socket, BMW No. 33 6 641. Insert circlips (1, 5) on left and right with the hook toward the outside. X Tightening torques: Swinging arm to frame Release the left/right bearing stud..............
PAGE 305
Removing and installing suspension strut • a • a • a • a Remove left and right fairing side sections. ....................................................See Group Remove left and right rear footrest plates. ....................................................See Group Remove the right-hand battery cover. ....................................................See Group Remove fuel tank. ....................................................
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33.
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34 34 Brakes Contents Page Technical Data ............................................................................................................................... 3 Front brake calliper .....................................................................................................................5 Removing and installing front brake calliper Removing and installing filler adapter .......................................................................5 ...................................
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Contents Page Removing and installing front brake lines/hoses .....................................................19 Removing front brake lines/hoses .........................................................................................19 Preparatory work ...............................................................................................................................19 Brake lines under fuel tank ..........................................................................................
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34 Technical Data K 1200 LT Brake fluid DOT 4 Brake actuation Hydraulic Front wheel Front brake 4-piston fixed callipers, floating discs Brake disc dia. mm (in) 305 (12.0) Brake disc thickness mm (in) 5.0 (0.20) Minimum thickness Brake pad surface area mm (in) 4.5 (0.18) mm2 (sq in) 2460 (3.81) Minimum lining thickness mm (in) 1.0 (0.04) Piston dia. in brake calliper mm (in) 32/34 (1.26/1.34) Wheel cylinder dia. mm (in) 16 (0.6) Sensor gap, front mm (in) 0.45 ... 0.55 (0.018 ... 0.
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34.
PAGE 311
Front brake calliper Removing and installing front brake calliper d Warning: Do not separate the two halves of the brake calliper. e Caution: Do not allow brake fluid to come into contact with 34 1 500 painted parts of the motorcycle or with the brake pads. – KL000080 • Drain the brake system. • a • 1 If necessary, press the brake pads/pistons fully back with resetting tool, BMW No. 34 1 500. Fill and bleed the brake system. ....................................................
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Removing and installing filler adapter – – 34 1 500 Remove right-hand brake calliper. Remove the brake pads. e Caution: Make sure no traces of thread-locking compound penetrate the brake callipers. KL340250 • • w 80 1 • • • • h KL340230 Clamp the brake calliper in a vise. Filler adapter (1) must point down to ensure that no traces of thread-locking compound can penetrate into the brake calliper when the filler adapter is slackened. Heat filler adapter (1) to approx.
PAGE 313
Removing and installing front brake pistons Rear brake calliper – Removing and installing rear brake calliper • • Remove the brake calliper. Use piston resetting tool, BMW No. 34 1 500, to locate two opposing brake pistons. Insert a piece of cloth between the two brake pistons not located by the resetting tool. d Warning: Do not allow your fingers to become trapped between the pistons; risk of injury.
PAGE 314
L Note: Removing and installing rear brake pistons Clean ABS sensor and bore before removing/installing. – – a • • • Remove rear brake calliper. Remove the brake pads. ....................................................See Group 00 Remove pressure pads from brake pistons. Use piston resetting tool, BMW No. 34 1 500, to locate two opposing brake pistons. Insert a piece of cloth between the two brake pistons not located by the resetting tool.
PAGE 315
Removing and installing front brake disc – a Remove front wheel. ....................................................See Group 36 Removing and installing rear brake disc – a – 1 Remove rear wheel. ....................................................See Group 36 Remove the brake calliper. L Note: Mark the installed position of the brake disc on the rear wheel drive, so that vertical runout of the sensor ring is not altered.
PAGE 316
Removing and installing front ABS sensor – Remove right side section of fairing. e Caution: 4 Disconnect ground lead from battery and insulate. • Remove the left brake calliper. 5 1 KR340040 • • • Release the fasteners (arrows) for ABS sensor (5). Take off ABS sensor (5) with spacing plate (4). Installation is the reverse of the removal procedure: pay particular attention to the following. e Caution: Carefully route the ABS cable and secure in position with cable ties.
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Adjusting front ABS sensor Checking/adjusting ABS sensor gap Marking the ABS sensor ring – – Checking ABS sensor gap Take load off front wheel and lift clear of ground. Take load off front wheel and lift clear of ground. 1 4 2 34 2 510 00 2 510 00 2 500 3 KL340120 • • • • Remove clamping screw from left fork tube. Secure dial gauge holder, BMW No. 00 2 500, with dial gauge, BMW No. 00 2 510, and measuring shoe, BMW No. 34 2 510, to fork slider tube. Zero the dial gauge.
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Removing and installing rear ABS sensor e Caution: Disconnect ground lead from battery and insulate. Adjusting rear ABS sensor Marking the ABS sensor ring – – Remove rear wheel. Remove the ABS sensor. 00 2 510 1 34 2 510 00 2 661 2 00 2 500 KL340090 KL340070 – • • Clean ABS sensor (1) and bore before removing and installing. Remove screws securing ABS sensor (1) from brake calliper. Remove ABS sensor (1) with spacing plate (2).
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Checking/adjusting ABS sensor gap Checking ABS sensor gap Removing and installing rear brake master cylinder e Caution: Do not allow brake fluid to come into contact with 1 2 painted parts of the motorcycle, because brake fluid destroys paint. – – Drain the brake system. Remove right footrest plate. 3 4 KL340100 • • 7 6 Align the marked point on sensor ring (1) with ABS sensor (2). Use ABS feeler gauge (arrow) to check the gap between the ABS sensor and the sensor ring.
PAGE 320
Checking/adjusting play at piston rod d Warning: All adjustments must be performed by an authorised BMW dealer. Adjusting play at piston rod d Warning: First adjust the brake light switch for the foot brake. • Remove right footrest plate. Checking play at piston rod 2 1 KL340140 KL340130 • 3 Use a feeler gauge (arrow) to check the gap between the brake-light switch plate and adjusting screw (1). Feeler gauge thickness ............... 0.5 mm (0.
PAGE 321
Removing and installing ABS control unit 1 d Warning: All work on the ABS control unit must be carried out by an authorised BMW workshop. 2 e Caution: Disconnect the negative battery terminal first, then the positive one. – a – – a – – Remove the battery. .......................................See Group 00, Battery Drain front and rear brake systems. Remove left and right rear footrests. ....................................................See Group 46 Remove left and right fairing side sections.
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1 3 KL340170 • Remove retaining plate (1) for brake line from the battery carrier. KL340210 • Remove battery carrier (3), if necessary. 4 5 2 3 KR340390 KL340060 • • Slightly raise ABS control unit (2) complete with battery carrier (3) and pull the assembly toward the rear. Release the retaining screws (arrows). • • Using a small screwdriver, press end cover (5) of ABS relay housing (4) in (arrow) and at the same time pull end cover (5) upwards. Scrap the old cover (5).
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• • • Installation is the reverse of the removal procedure: pay particular attention to the following. Install a new end cover for the ABS relay housing. Route all cables correctly and secure with cable ties. Removing and installing ABS relay e Caution: Disconnect the negative battery terminal first, then the positive one. L Note: The front fastener (long pointed screw) of the left- – hand rear footrest plate is also the anchorage point for the battery carrier.
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1 6 2 7 KR340390 • • Using a small screwdriver, press end cover (2) of ABS relay housing (1) in (arrow) and at the same time pull end cover (2) upwards. Scrap the old cover (2). KL340160 • • • • Pull ABS relay (6) and ABS relay base (7) out of the housing. Loosen fasteners (arrows). Pull ABS relay (6) up out of ABS relay base (7). Installation is the reverse of the removal procedure: pay particular attention to the following.
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KL340030 Removing and installing front brake lines/hoses Removing front brake lines/hoses Preparatory work – Remove left and right fairing side sections. – Remove the left-hand battery cover. d Warning: Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressurised. – a Remove fuel tank. ....................................................See Group 16 KL610070 – Remove securing screws (arrows) and remove retaining plate for plug connectors. 34.
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e Caution: 3 Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint. Wrap cloths around the ends of the pressure lines to prevent residual brake fluid escaping. • • Drain the brake system. Open cable ties securing brake hoses, as necessary. 2 1 KL310170 • • Remove retaining plate (3) for brake lines at front of main frame. Disconnect brake lines (1) and remove. Brake line/hose to telescopic fork Remove the brake callipers.
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Brake hose to handlebar – Remove left and right handlebar trim. a ....................................................See Group 46 – Remove cover of fork bridge. • Turn the brake fitting until the banjo bolt of the brake fluid reservoir is accessible. • Disconnect the brake hose from the brake fluid reservoir. Installing front brake lines/hoses • Installation is the reverse of the removal procedure: pay particular attention to the following.
PAGE 328
1 KL340040 Removing and installing rear brake lines/hoses Removing brake lines/hoses Preparatory work – Remove left and right fairing side sections. a ....................................................See Group 46 – Remove left and right battery covers. e Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint. Wrap cloths around the ends of the pressure lines to prevent residual brake fluid escaping. – Drain the brake system.
PAGE 329
Brake hose to brake master cylinder – Remove right engine spoiler. • Remove the front right footrest plate. Brake fluid reservoir with return hose • Remove the front right footrest plate. • Open non-reusable hose clip (4) and disconnect return hose (1). • Remove brake fluid reservoir with return hose. Brake line to brake calliper 2 1 e Caution: 4 3 Disconnect the negative battery terminal first, then the positive one. – Remove the battery.
PAGE 330
• • • • Disconnect brake lines from ABS pressure modulator. Open cable ties securing wiring harness to rear frame. If applicable, disconnect plug for seat heating on rear frame. Remove positive and negative terminals from frame. 2 KL340180 • Remove the holder (2) for the front brake lines from the main frame. 46 5 640 KL340200 • • Disconnect brake hose to brake calliper at retaining plate/union. Remove securing screw (arrow) securing retaining plate/union to rear frame.
PAGE 331
Installing brake lines/hoses • • • Installation is the reverse of the removal procedure: pay particular attention to the following. Apply Loctite 243 to threads of lower fasteners securing rear frame to main frame. Carefully re-route all lines in their original positions and secure with cable ties. e Caution: Renew sealing rings at brake line/hose. Checking brake pads for wear/ replacing brake pads See Group 00 Checking brake fluid level See Group 00 Always secure brake hose with stop plate.
PAGE 332
34.
PAGE 333
36 36 Wheels and tyres Contents Page Technical data ................................................................................................................................ 3 Removing and installing front wheel .................................................................................5 Removing and installing wheel bearings Removing left/right wheel bearings ........................................................................6 ......................................................
PAGE 334
36.
PAGE 335
36 Technical data Rim size K 1200 LT Front Rear 3.50”x17” MT H 2 5.00”x17” MT H 2 Vertical runout Front Rear mm (in) 0.5 (0.02) mm (in) 0.3 (0.01) Front Rear mm (in) 0.5 (0.02) mm (in) 0.3 (0.01) Front Rear mm (in) 120/70 R17 58 V tubeless mm (in) 160/70 R17 79 V tubeless Lateral runout Tyre size Tyre pressures (tyres cold) Solo/two-up Front Rear bar (psi) 2.5 (36.3) bar (psi) 2.9 (42.0) Two-up with luggage Front Rear bar (psi) 2.5 (36.3) bar (psi) 3.2 (46.
PAGE 336
36.
PAGE 337
4 1 2 3 6 5 KL360011 Removing and installing front wheel – a Remove front section of front mudguard. ....................................................See Group 46 e Caution: • • Installation is the reverse of the removal procedure: pay particular attention to the following. Grease the quick-release axle (1) and bearing cover (3) lightly with Shell Retinax EP2. L Note: Begin by tightening the quick-release axle (1). Press Avoid scratching the wheel rim; if necessary mask off the brake caliper.
PAGE 338
1 2 3 4 KR360020 Removing and installing wheel bearings • 00 8 570 00 8 574 Place the front wheel on two wooden battens (make sure the brake disc is clear of the ground and the battens). w h 100 36 6 640 Removing left/right wheel bearings L Note: There is no circlip at the right wheel bearing. • • Lever out shaft seal (1). Remove circlip (2) with circlip pliers. KR360060 • Place support ring, BMW No. 36 6 640, on wheel hub. L Note: Use temperature measuring device, BMW No.
PAGE 339
Installing right/left wheel bearing e Caution: When installing, always start with the left side. Installing right wheel bearing • Install the spacer bushing. e Caution: When pressing in the right wheel bearing, make sure that the left wheel bearing does not lift off its seat. Installing left wheel bearing • • • 00 5 500 36 5 512 h 100 w Chill the wheel bearing. Heat bearing seat to 100 °C (212 °F). Using handle for drift, BMW No. 00 5 500, and drift, BMW No.
PAGE 340
Removing/installing rear wheel Installing rear wheel Removing rear wheel – – • Select first gear. Remove number plate carrier. The contact faces on the spacing washer, the rear wheel drive and the wheel hub must be free from grease and clean. KL460040 KL360020 • • Unscrew wheel studs (arrow). Remove rear wheel with spacing washer to the rear. e Caution: Use only wheel studs marked 55 (arrow) to indicate length.
PAGE 341
36 3 607 36 3 618 36 3 619 36 3 621 36 3 622 1 2 36 3 600 S360050 Static balancing of front and rear wheels Static balancing of rear wheel Static balancing of front wheel L Note: – – • • • • • Level balancer, BMW No. 36 3 600, using knurled-head screws (2) and spirit level (1). Insert the balancing shaft, BMW No. 36 3 621, through the front wheel. Hand-tighten the balancing shaft with knurled nut, BMW No. 36 3 622. Place front wheel on balancer, BMW No. 36 3 600.
PAGE 342
36 3 621 36 3 622 00 2 510 1 2 36 3 600 KR360080 Checking front/rear wheel rim for run-out Checking front wheel rim for run-out L Note: Bring the stylus of the dial gauge, – – BMW No. 00 2 510, into contact with the machined inner surface of the wheel rim only. • • • • • Remove tyre. Level balancer, BMW No. 36 3 600, using knurled-head screws (2) and spirit level (1). Pass the balancing shaft, BMW No. 36 3 621, through the front wheel. Hand-tighten the balancing shaft with knurled nut, BMW No.
PAGE 343
36 3 618 36 3 607 36 3 619 00 2 510 1 2 36 3 600 KR360050 Checking rear wheel rim for run-out – – • • • • • • Remove tyre. Level balancer, BMW No. 36 3 600, using knurled-head screws (2) and spirit level (1). Secure the mounting device, BMW No. 36 3 618, to the centering-collar side of the rear wheel. Pass the balancing shaft, BMW No. 36 3 607, through the rear wheel. Hand-tighten the balancing shaft with knurled nut, BMW No. 36 3 619. Place the rear wheel on the balancing stand, BMW No. 36 3 600.
PAGE 344
36.
PAGE 345
46 46 Frame Contents Page Technical Data ............................................................................................................................... 5 Overview of fairing sections, K 1200 LT ..........................................................................7 Removing and installing fairing side section Removing and installing mirror ................................................................8 ...........................................................................
PAGE 346
Contents Page Removing and installing left/right handlebar trim Removing and installing fork bridge cover Removing/installing interior trim ....................................................19 ..................................................................19 .......................................................................................20 Removing and installing left/right wind deflectors Removing and installing front mudguard ..................................................20 .......
PAGE 347
Contents Page Removing and installing side case ........................................................................................32 Removing and installing side case lid ..................................................................................33 Removing and installing rear moulding ...............................................................................33 Removing and installing rear carrier section ....................................................................
PAGE 348
46.
PAGE 349
46 Technical Data K 1200 LT Location of type plate/frame number Beneath seat, panel on right-hand side at rear frame Dimensions Overall length mm (in) 2508 (98.7) Maximum height ECE/US (windscreen retracted) mm (in) 1395/1475 (55.0/58.1) Maximum height (aerial) mm (in) 1915 (75.4) Maximum width across mirrors mm (in) 1080 (42.5) Height of seat at unladen weight mm (in) 770/800 (30.3/31.5) Top case, capacity l (Imp. gal/ US gallons) 50 (11/13.2) Side case, capacity l (Imp.
PAGE 350
46.
PAGE 351
KL469000 Overview of fairing sections, K 1200 LT 46.
PAGE 352
1 2 3 KL460010 Removing and installing fairing side section Removing and installing mirror Removing and installing fin • • Release 3 fasteners (2). Remove fin (1). Removing and installing front turn indicator • • • • 4 5 6 KL460180 L Note: The gap at the mirror can be evened out by means of washers (4, 5) on the front bolt. • • • • Hold the mirror casing with one hand and remove it by gently tapping/pressing with the other.
PAGE 353
1 2 3 5 4 Removing and installing bottom of tank cover – – • • KL460010 Removing skirt Open the front seat. Open the flap of the radio control unit. Release 2 fasteners (1). Move bottom of tank cover (2) down to disengage and remove. • • • • Release 3 fasteners (4). Remove skirt (5). Installation is the reverse of the removal procedure: pay particular attention to the following. Make sure that all 3 hooks (arrow) of the fairing skirt (5) engage the fairing side section.
PAGE 354
1 2 KL460010 Removing and installing fairing side section • Release 10 fasteners (2). • Install securing screws (1). L Note: When installing, note the position of the front corner (arrow) of the fairing side section relative to the engine spoiler. 3 4 • • [Right] Install 9 fasteners in clockwise direction. [Left] Install 9 fasteners in counter-clockwise direction. X Tightening torques: Fairing screws ................................................
PAGE 355
1 2 KL460190 Removing and installing tank cover – • Removing flap of radio compartment Remove fairing side sections. Release 6 fasteners (1). 7 8 6 3 4 9 5 KL460400 KL610380 • • • • • • Disengage lines from holder (5). Disconnect plug (3) at retaining plate under interior trim. Disconnect plugs (4) at tank cover. Remove radio control unit Installation is the reverse of the removal procedure.
PAGE 356
1 2 3 4 8 7 6 5 KL460110 Removing and installing engine spoiler • • • Remove reverser actuating control (3). [Left] Remove plug (1) for on-board power socket (2). Remove 3 anchorages (4) on engine-spoiler side section. L Note: The centre section of the engine spoiler can be removed complete with one side section. • • • • Remove a set of 5 fasteners from the engine spoiler centre section (7). Remove 3 fasteners (5) from skirt. Remove engine spoiler (6, 7, 8).
PAGE 357
7 6 5 1 2 4 3 KL460080 Removing/installing components mounted on side section of fairing Removing air outlet duct • • Release 4 fasteners (1). Remove air outlet duct (2). • Installation is the reverse of the removal procedure. Removing kneepad • • Release 7 fasteners (4). Remove kneepad (5). Removing grille • • Release 3 fasteners. Remove grille (3). Removing badge • • Release 3 fasteners. Disengage badge (7) (arrow) and remove.
PAGE 358
1 2 3 6 5 Removing and installing battery cover – Remove fairing side section. L Note: The bottom fastener of the left-hand rear footrest plate is also the anchorage point for the battery carrier. When removing the battery cover, slacken but do not remove this screw. – • • • • • • • • • Slacken screw securing rear footrest plate. Open case. Open the front seat. Remove fastener (arrow) from cover. [Left] Remove the rear seat. [Left] Remove fasteners (1, 3) securing lifting handle (4).
PAGE 359
1 2 3 4 KL460140 Removing windscreen Removing windscreen cover • • Slightly raise the windscreen. From the inside (arrow), unclip windscreen cover (2) from its mount (3). Removing windscreen • • Remove 4 fasteners (1) (micro-encapsulated). Remove windscreen and retaining plates (4). • Installation is the reverse of the removal procedure: pay particular attention to the following.
PAGE 360
1 4 3 2 5 KL460360 Removing and installing windscreen adjuster – Remove upper section of fairing. e Caution: Do not separate the electric drive for the windscreen adjuster from its holder. • • • • • • • Open the cable ties (arrows). Disconnect plug (3). Remove plug (3) and relay (4) from fairing bracket. Remove 2 fasteners (1) securing interior trim to windscreen adjuster. Remove 5 fasteners (2, 5) securing windscreen adjuster to fairing bracket. Remove windscreen adjuster.
PAGE 361
2 3 1 4 5 6 KL460230 Removing and installing instrument cover • • • • • • • From the left (arrow), unclip the light from the inner cover. Remove 1 fastener (5) behind the light. Remove 2 long fasteners (1) from the windscreen adjuster. Remove 2 long fasteners (3), 2 short fasteners (6) from below the cover. Remove instrument cover (2) with wind deflector (4). Remove wind deflector, if necessary. Installation is the reverse of the removal procedure. 46.
PAGE 362
8 1 2 3 7 6 5 4 KL460130 Removing and installing upper section of fairing – – – • • • • • • • Remove left and right fairing side sections. Remove windscreen. Remove instrument cover. Remove headlight adjuster (1). Disconnect temperature sensor (5) and parkinglight bulb (6). Disconnect plug for headlight (7). Remove 4 fasteners (3). Remove 5 fasteners (2, 4) from fairing bracket. Remove upper section of fairing.
PAGE 363
3 1 2 4 5 6 7 8 KL460220 Removing and installing left/right handlebar trim • • • • • 5 Release fasteners (8). Remove upper handlebar trim (3). Release fasteners (6). Remove lower handlebar trim (7). Installation is the reverse of the removal procedure. 9 Removing and installing fork bridge cover – – • • • • • Remove fairing side sections. Remove tank cover. Remove upper handlebar trim. Release fasteners (1). Remove fastener (4) from seal (5). Remove cover of fork bridge (2) and seal (5).
PAGE 364
1 2 3 4 6 5 7 KL460240 Removing/installing interior trim – – – – – • • • • Remove tank cover. Remove windscreen. Remove instrument cover (1). Remove handlebar trim. Remove cover of fork bridge. From the left, disconnect light (2). Disconnect plug (4) for lighting. Remove headlight adjuster (5). Remove screws (3, 6). • – • • L Note: Protect interior trim against scratching. Use masking tape to cover tabs (arrows) on handlebars and interior trim. 46.20 Carefully remove interior trim.
PAGE 365
1 4 2 3 KL460100 Removing and installing front mudguard Removing and installing front mudguard rear section Removing and installing front mudguard front section • • • • • • • • X • • • Release fasteners (3). Release fasteners (1). Remove front section of front mudguard. Remove bushes (4). Installation is the reverse of the removal procedure: pay particular attention to the following. Install securing screws (3). Tighten securing screws (1).
PAGE 366
2 1 10 3 9 4 8 7 5 6 Removing and installing front footrests • • a • • • Remove circlip (6) and pin (5). Remove footrest (8). Coat pin (5) with Optimoly MP3, tension torsion spring and install footrest. Removing and installing front right footrest plate e Caution: Do not overstretch brake lines and cables. Do not scratch the engine spoiler. • • • • • • Remove fasteners (7, 9). Carefully pull the footrest plate off its anchorage and turn it over.
PAGE 367
1 2 3 4 6 5 KL460070 Removing and installing front left footrest plate Removing and installing left/right rear footrest plates • • • • • • • Release 3 fasteners (4). Disengage ball joint (5) from gearshift lever. Remove footrest plate (1) with gearshift lever. Installation is the reverse of the removal procedure. X Tightening torque: Footrest plate, front, to frame ....................... 21 Nm Release 3 fasteners (2). Remove rear footrest plate.
PAGE 368
Removing and installing rear footrests 1 2 3 4 • KL460270 Remove circlip (3). L Note: When removing the stud, note the spring and ball in stop plate (1). • • • Remove stud (2) with spacer plate (1) and ball and spring. Installation is the reverse of the removal procedure. Coat stud (2) with Optimoly MP3. Disassembling rear footrest • • • Remove 3 fasteners from footrest rubber pad (4). Remove rubber pad and retaining plate. Installation is the reverse of the removal procedure.
PAGE 369
Disassembling and assembling side stand Removing and installing intake air pipe d Warning: Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressurised. • a Remove fuel tank. ...................................................See Group 16. KR460260 • • a • • Disconnect the tension springs and take off the plate with the springs. Remove switch for side stand (arrow). ...................................................
PAGE 370
1 2 3 4 5 KL460030 Removing and installing skirt bracket – • Removing and installing crash bar Remove right or left fairing side section and engine spoiler, as applicable. Open cable tie on skirt bracket (1). 8 9 6 10 7 12 11 • KL170060 • • • • [Right] Disconnect plug (6) at rear of skirt bracket. [Right] Remove retaining clip (7) with washer. Remove fasteners (2, 5) and remove skirt bracket. Installation is the reverse of the removal procedure. X Tightening torque: Skirt bracket M8..........
PAGE 371
Removing and installing radiator holder Removing and installing rearmounted components – Removing and installing number-plate carrier Remove left and right fairing side sections and tank cover. e Caution: Note safety precautions; the fuel lines are pressurised. – a – a Remove fuel tank. ....................................................See Group 16 Remove the left or right radiator, as applicable. ....................................................
PAGE 372
1 2 3 9 4 8 7 5 6 Removing and installing top case – • • Remove rear seat. Disconnect plugs (7) and disengage the cables from their holders (9). Open the top case. d Warning: Support the lid to prevent it falling closed. • • • • • • • • Support the lid (1). Release the knurled screw (6). Disengage the strap from the base of the top case. Use a screwdriver to unclip the removable lining (5) from the lock. Detach the Velcro strip (4) from the rear panel. Remove the lining.
PAGE 373
1 2 3 6 Disassembling top case Removing/installing interior light • From the left (arrow), unclip the light. • Disconnect plug. • Installation is the reverse of the removal procedure. Removing mirror and document stowage compartment • Remove 5 fasteners (4) and remove document stowage compartment (5) complete with mirror (3). • Installation is the reverse of the removal procedure. 5 4 KL460160 Removing lid of top case – Remove the top case. – Remove the backrest. – Remove left and right armrests (1).
PAGE 374
Removing and installing rear carrier cover – Remove the top case. 1 7 2 KL460370 8 L Note: Install plate with holes (1) as seat for rivet heads. Install retaining clip (2) for cable as illustrated, together with plate (1). • Use A4.0X12 pop rivets to secure the lid of the top case to the hinges. From this point on, installation is the reverse of the removal procedure. • X Tightening torque: Armrest to top case........................................
PAGE 375
1 2 3 4 9 8 5 6 7 KL460120 Removing and installing case trimmer – – – • • • • • Remove the top case. Remove the rear carrier cover (8). Remove number plate carrier (7). Release fasteners (6) and remove rear light (4). Disconnect plug (1). Pull cable with rubber grommet (9) out of case trimmer. Release fasteners (2, 5) and remove case trimmer. Installation is the reverse of the removal procedure. X Tightening torques: Case trimmer to rear frame (2)........................
PAGE 376
Removing and installing side case – – – – • • Remove the number plate carrier. Remove the top case. Remove the rear carrier cover. Remove the case trimmer. [Left] Disassemble knob for seat latch. [Right] Remove CD player, if applicable. 3 KL460380 • • • 1 KL460121 • • Slacken right or left rear footrest plate, as applicable. Remove fasteners for battery cover (1) on left or right case, as applicable and loosen battery cover.
PAGE 377
1 2 3 KL460170 Removing and installing side case lid Removing and installing rear moulding • e Caution: Drill out rivets. d Warning: Do not overheat plastic parts and paint. The strap winder is spring-loaded: risk of injury if retaining plate (2) is allowed to snap loose. • • • • • • • • • Remove fastener (1) securing strap to lid of case. Remove lid of case. Remove shanks of rivets. Use A4.8X16 pop rivets to secure lid to hinges (3). Secure strap to lid of case.
PAGE 378
1 3 2 4 5 KL460090 Removing and installing rear carrier section Removing rear mudguard – • • Remove left and right side cases. – • • 6 • • • • • • 7 KL460380 Open the cable ties (arrows). Disconnect plug (7). Pull round plugs and cables out of their holders. [Activated charcoal filter] Remove activated charcoal filter (6). Release 4 fasteners (1, 2, 3) and remove rear carrier (4). Installation is the reverse of the removal procedure. 46.34 Remove left and right side cases.
PAGE 379
2 1 3 4 Removing and installing front fairing bracket – – – – • • • • • • • • – a • Remove upper section of fairing. Remove interior trim. Remove instrument panel. Remove left and right skirt brackets. Remove air outlet ducts for radiators. Slacken the right-hand radiator. Remove the electric windscreen adjuster. Remove cruise control system with retaining plate. Remove cable ties and plugs from fairing bracket. Remove fanfare horns on left and right. Remove the intake air pipe.
PAGE 380
Removing reflectors – Removing and installing retaining plates in front of fork bridge Remove upper section of fairing. – – 1 Remove upper section of fairing. Remove interior trim. e Caution: Note safety precautions; the fuel lines are pressurised. 2 – a – 5 Remove fuel tank. ....................................................See Group 16 Remove handlebar trim and fork bridge cover. 6 4 3 KL460052 7 8 9 Removing upper reflector • Release 4 fasteners (1, 3) and remove upper reflector (2).
PAGE 381
36 3 920 2 1 KL460260 Checking running gear • Measuring wheel track offset Release tension in the track alignment gauge by raising it by approx. 5 mm (0.2 in) at the front and lowering it again. L Note: Wheel track offset S is the distance to left or right between the longitudinal axes of the front and rear wheels. • • • Place the motorcycle on its main (centre) stand on a flat, level surface. Measure wheel rim width at front and rear and make a note of the figures.
PAGE 382
Example B Formula: Fv Fv Fh S = A + ---- –  B + ----  2 2 Fixed value A (length of measuring stops) B A = 50.0 mm (1.97 in) Half of rear wheel rim width Fh ---- = 72.5 mm (2.85 in) 2 S Measured value B (average value) B = 68.4 mm (2.69 in) A Fh Half of front wheel rim width Fv ---- = 55.8 mm (2.20 in) 2 A KR460480 • Measure or calculate the length of the stops accordingly (distance A). • Measure the width of the rims front (Fv) and rear (Fh) and note down the measured values.
PAGE 383
KL469021 Removing and installing frame 46.
PAGE 384
46 5 640 KL460021 Removing and installing rear frame L Note: Lower the windscreen if the main frame has to be removed. – – – – – – • • • • • • • • • • • • a Disconnect negative cable from battery and insulate it. Remove left and right fairing side sections. Remove left and right battery covers. Remove left and right rear footrests. Remove the front and rear seats. Remove the rear-mounted components. Disconnect plugs of rear wiring harness. Disconnect fuse boxes from holder for seat latch release.
PAGE 385
1 2 KL460020 • • • • • Remove fasteners (2) securing rear frame to main frame at bottom. Remove protective cap from top fastener for rear frame. Remove fasteners (1) securing rear frame to main frame at top. Remove rear frame with workshop crane, BMW No. 46 5 640. Installation is the reverse of the removal procedure: pay particular attention to the following. X Tightening torques: Rear frame to main frame, top...................... 41 Nm Rear frame to main frame, bottom (clean thread + Loctite 243)....
PAGE 386
Removing and installing cross-tube Preparatory work • Remove left-hand side of engine spoiler. • Remove right and left front footrest plates (it is not necessary to remove the brake and gearshift levers). • Remove fasteners securing the exhaust system (it is not necessary to unplug the oxygen sensor). Additional preparations for removing engine, gearbox or main frame • Remove exhaust system. • Remove rear wheel. • Drain oil from rear wheel drive.
PAGE 387
Removing and installing left/right engine cross-member e Caution: • • Remove throttle-valve rail complete with intake air silencer. Attach hoist, BMW No. 00 1 510, to oil sump. 1 Note safety precautions; the fuel lines are pressurised. – – • • Remove fuel tank. Remove left and right sections of engine spoiler. [Right] Remove the air intake pipe. Remove left and right skirt brackets.
PAGE 388
Removing main frame – – – – • • • Remove the rear frame. Remove transverse tube. Remove left/right engine cross-member. Remove the battery. Remove handlebar trim on left and right and remove cover for fork bridge. Drain the clutch and brake systems. Remove windscreen, upper section of fairing and interior trim. 3 1 • • • • • KL460051 Remove Remove Remove Remove 5 KL120040 2 • • • • 4 retaining plate (2) for plug connectors. retaining plate (1). the rear suspension strut.
PAGE 389
• • • • • Remove fork bridge. Remove front suspension strut. Remove the leading link. Remove the leading link bearing. Release screws securing gearbox to frame. Union, brake hose and brake line................. 18 Brake line to ABS pressure modulator ......... 18 Brake hose to brake calliper......................... 18 Brake line at master cylinder ........................ 18 Master cylinder to footrest plate (clean thread + Loctite 243)............................
PAGE 390
Lifter handle to rear frame M 6 ...................... 9 Nm Seat, rear, to rear frame ................................. 9 Nm Skirt bracket M 8.......................................... 21 Nm Footrest system rear to frame....................... 21 Nm Cover of fork bridge to holder......................... 2 Nm Trim panels .................................................... 2 Nm 46.
PAGE 391
51 51 Equipment Contents Page Removing and installing ignition switch/steering lock ...........................................3 Removing and installing lock barrel ........................................................................................3 Removing the lock barrel .....................................................................................................................3 Removing lock barrel if ignition key has broken off ......................................................
PAGE 392
51.
PAGE 393
51 Removing and installing ignition switch/steering lock Removing and installing lock barrel – L Note: The lock barrel can also be removed when the fork a Remove fork bridge. ....................................................See Group 31 Removing the lock barrel bridge is installed. – a – – – – Remove left and right fairing side sections. ....................................................See Group 46 Remove left and right handlebar trim sections. Remove tank cover. Remove cover of fork bridge.
PAGE 394
Disassembling/assembling fuel tank lock Removing and installing fuel tank lock barrel Removing and installing flap for tank cap – – • Remove fuel cap. Slightly straighten the 4 lugs in the underside of the grip one after the other and remove the barrel from the grip. Remove tank cover. 3 1 4 5 6 2 KL510020 KL510110 • • • • Remove locking pints (1) on left and right. Remove studs (2) on left and right. Remove flap for tank cap. Installation is the reverse of the removal procedure.
PAGE 395
Removing and installing lock barrel of fuel tank cover – a Remove front seat with bridge. ....................................................See Group 52 KL510120 • Remove screws (arrows) and remove the lock. KL510160 • • • • • Insert key and turn to OPEN position. Insert a length of wire or similar through bore (arrow) and press in the locking pin. Use the ignition key to remove lock barrel. Grease lock barrel with Retinax EP 2. Installation is the reverse of the removal procedure. 51.
PAGE 396
5 2 1 3 6 7 4 7 8 KL510060 Removing and installing locking system for front seat – a – a Remove left trim panel and battery cover. ....................................................See Group 46 Remove rear seat. ....................................................See Group 52 9 Removing locking system • • • • • • • Unclip fuse box (5) and pull forward to remove. [Seat heating] Unclip plug (6). Remove screws (7) and remove lock hook complete with holder.
PAGE 397
1 2 3 4 5 KL510040 Removing and installing lock barrel of side case – Removing and installing lock barrel of top case Open the side case. L Note: Note positions of retaining plates (4, 5). • Remove retaining plates (4, 5). d Warning: The strap roller is spring-loaded: risk of injury if metal fastener (2) is suddenly released. • • • • • • • • Remove screw (1) securing strap to flap of side case. Remove cover plate (3). Remove handle complete with lock. Insert key and turn to OPEN position.
PAGE 398
51.
PAGE 399
52 52 Seat Contents Removing and installing seat Page .................................................................................................3 Removing and installing front seat with bridge ..................................................................3 Removing and installing rear seat ...........................................................................................
PAGE 400
52.
PAGE 401
52 1 2 KL460040 Removing and installing seat Removing and installing rear seat Removing and installing front seat with bridge – – – • • • • Remove left and right fairing side sections. Remove tank cover. [Seat heating] Disconnect plug for seat heating. Remove 5 screws (arrows) and remove seat and bridge. Installation is the reverse of the removal procedure: pay particular attention to the following. Note rubber washer (1) and grommet (2). X Tightening torques: Bridge, seat to frame M 6............
PAGE 402
Disassembling/assembling front seat Removing and installing gas-filled strut Removing and installing front seat • – – Remove front seat. Remove retainer (1) and disengage gas-filled strut. Open hinged seat. 3 1 KL460280 • • 3 2 KL460042 • • Remove screws (2) and remove seat. Installation is the reverse of the removal procedure. X Tightening torques: Seat to retaining plate .................................... 5 Nm 52.
PAGE 403
61 61 General electrical equipment Contents Page Technical Data ............................................................................................................................... 3 Wiring harness View from right View from left ...............................................................................................................................5 .................................................................................................................................5 ......
PAGE 404
Contents Page Removing and installing control unit for reverser ....................................................18 Removing and installing inductive sensor for speedometer ..............................19 Removing and installing water temperature sensor Replacing side stand switch ................................................................................................20 Removing and installing side stand switch Check operation of side stand switch .........................................
PAGE 405
61 Technical Data Circuit voltage Battery Power sockets (standard equipment) K 1200 LT V 12 A/h 19 2 61.
PAGE 406
61.
PAGE 407
Wiring harness View from right KL619010 61.
PAGE 408
View from left KL619020 61.
PAGE 409
Rear frame wiring harness KL619030 61.
PAGE 410
Top case wiring KL610050 61.
PAGE 411
Tank cover with radio/cassette player KL610040 Connectors beside ABS control unit KL610200 61.
PAGE 412
1 10 2 9 3 4 6 5 Connectors on fairing bracket 1 2 3 4 5 6 7 8 9 10 Relay for lowering adjustable windscreen Brake-light switch, front brake Switch for cruise control system Switch for heated grips Temperature sensor Clutch switch for cruise control system Clutch switch for starter motor ABS sensor for front brake On-board computer Relay for raising adjustable windscreen 61.
PAGE 413
5 4 3 2 1 6 7 8 9 Relay positions in electronics box 1 2 3 4 5 6 7 8 9 KR610080 Connectors, electronics box Starter relay ABS warning relay Relief relay Fuel pump relay Control unit for fuel warning light Flasher unit Motronic relay Horn relay Fan relay 16 10 11 17 18 12 13 14 19 20 15 KL610240 10 11 12 13 14 15 16 17 18 19 20 Hall-effect sensor Multi-function switch, right Ignition light switch Instrument cluster Instrument cluster 2 Multi-function switch, left Water pump temperature sensor O
PAGE 414
Handlebar wiring KL320020 KL320030 61.
PAGE 415
5 6 7 4 3 2 1 8 9 10 11 12 KL610020 Replacing fuses Fuse for radio/cassette player Motorcycle fuses – – • • a Remove radio/cassette player. ....................................................See Group 65 Lift the seat at the front. Open the cover of the fuse box. Replace the defective fuse.
PAGE 416
Removing and installing electronics box e Caution: Disconnect ground lead from battery and insulate. – Remove left and right fairing side sections. d Warning: Comply with safety precautions when handling or working with fuel. – a – a – – – Remove fuel tank. ....................................................See Group 16 Remove Motronic control unit. ....................................................See Group 13 Remove the right-hand air intake pipe.
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11 1 2 3 4 10 9 7 6 8 5 KL320051 Disassembling left multi-function switch • Preparatory work Press radiator out of holder. 12 e Caution: Disconnect ground lead from battery and insulate. – a – – • • • • • Remove left-hand handlebar trim. ....................................................See Group 46 Remove left and right fairing side sections. Remove cover of fork bridge. Open cable ties on handlebar. Release fastener (2) and swing radio control unit (5) clear.
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Disassembling right multi-function switch e Caution: Disconnect ground lead from battery and insulate. – a – – 1 • • • • KL610170 Disconnect plugs (1) at fairing bracket. Open the cable ties. Pull cable through toward handlebar and remove switch. Installation is the reverse of the removal procedure. Removing left multi-function switch Removing and installing right multi-function switch d Warning: Comply with safety precautions when handling or working with fuel.
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1 2 6 4 3 5 KL320041 Removing brake light switch 7 9 8 KL610150 • • • • • • • • Open the cable ties (arrows). Disconnect plugs (8) in electronics box. Disconnect plug (7) at fairing bracket. Pull cable through toward handlebar. Release fasteners (3) and take off lower cover (4). Release fasteners (5, 6) and remove multi-function switch. Installation is the reverse of the removal procedure: pay particular attention to the following.
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Removing and installing control unit for reverser – a – – – Remove left side section of fairing. ....................................................See Group 46 Remove the rear left footrest plate. Remove the left-hand battery cover. Remove rear seat. 5 e Caution: To avoid short-circuits: Disconnect negative battery lead (—) first, then positive (+) lead. – KL610230 Remove the battery. • • • 1 2 3 x 4 KL610220 • • • • • • • Open the cable ties (arrows). Disconnect plugs (1, 2).
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Removing and installing inductive sensor for speedometer Removing and installing water temperature sensor – – a – Remove right side section of fairing and battery cover. ....................................................See Group 46 Remove rear seat. a – – a – a Remove left side section of fairing and battery cover. ....................................................See Group 46 Remove left-hand and centre sections of engine spoiler. Drain coolant. ..............................................
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Replacing side stand switch • Removing and installing side stand switch Installation is the reverse of the removal procedure: pay particular attention to the following. e Caution: Install screw and nut with Loctite 243. L Note: When installing, note the correct positions of the cable straps. X Tightening torques: Side stand switch fastener ............................. 7 Nm (clean thread + Loctite 243) Check operation of side stand switch KL610080 • • Disconnect plug (arrow).
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Replacing and adjusting foot brake light switch Adjusting brake light switch Removing and installing brake light switch – a 1 A – Remove right engine spoiler. ...................................................See Group 46. Remove the right footrest plate KL610160 • • • • KL610090 Slacken locknut (1). Set stop of foot-brake lever to distance “A”. Tighten the locknut. Check operation of brake-light switch. d Warning: Check piston rod play. • • Open the cable ties. Disconnect plug (arrow).
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Removing and installing ignition switch/steering lock cable • – • • Remove left and right fairing side sections. • d Warning: Comply with safety precautions when handling or working with fuel. – Remove fuel tank. Installation is the reverse of the removal procedure: pay particular attention to the following. Seal the tapped bore for the grubscrew with sealing lacquer. Carefully route the cable and secure in position with cable ties.
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Removing and installing switch for gear indicator Removing and installing power socket – Socket on engine spoiler a – – Remove left side section of fairing. ....................................................See Group 46 Remove the left-hand battery cover. Remove cross-tube. – a Remove left-hand side of engine spoiler. ....................................................See Group 46 2 1 KL610201 • • Disconnect plug (1). Open cable ties (arrows) and pull cable down to remove.
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Removing and installing cable for oil pressure switch / cable for water pump temperature sensor – a – Installing cables • Introduce the cable into the bore in the pump housing. Remove the cover from the Hall-effect transmitter. ....................................................See Group 12 Open the lid of the electronics box. Removing cables 1 2 KR610280 • • KL610270 • • Remove protective cap and plug from oil-pressure switch (1) / temperature sensor for water pump (2).
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62 62 Instruments Contents Page Technical Data ............................................................................................................................... 3 Wiring colours ................................................................................................................................5 Removing and installing instrument panel Replacing telltale/warning lights Telltale/warning lights .....................................................................6 ............
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62.
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62 Technical Data K 1200 LT Instrument cluster (standard) Speedometer, rev. counter, fuel gauge, clock, gear indicator, water-temperature gauge Turn indicator repeaters 12 V 1.7 W DIN 72 601 Other telltale lights, instrument lighting 12 V 1.7 W DIN 72 601 62.
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62.
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2 4 3 5 1 6 7 29 8 17 28 18 19 20 21 22 23 9 27 10 11 26 25 24 16 15 14 13 12 KL620060 Wiring colours 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 black green/black grey//blue, brown/blue brown, brown/red blue/green yellow grey/blue, brown/blue grey/blue, brown/blue yellow/violet green/black brown brown/black, green/black green/black, blue brown/blue, white green/black, brown/green white/green, green/black blue/black, brown/blue green/black, brown/yellow
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1 6 2 3 5 4 KL620020 Removing and installing instrument panel – a – – – – • • • • Remove left and right fairing side sections. ....................................................See Group 46 Remove left and right handlebar trim. Remove cover of fork bridge. Remove upper section of fairing. Remove instrument cover. Release fasteners (6). Disconnect plug (3) for the clock. Pull the instrument cluster out of holder (2). Remove the telltale lights (5).
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1 2 3 9 17 16 10 11 12 13 14 15 8 7 Replacing telltale/warning lights L Note: If necessary, pull gently on the cables to release the telltale/warning lights. – a • • • • Remove instrument cover. ....................................................See Group 46 Pull out the appropriate holder with telltale/warning light. Renew the telltale/warning light. Press the telltale/warning light holder as far as possible into the instrument cluster. Installation is the reverse of the removal procedure.
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5 4 3 2 6 7 1 8 10 9 Disassembling instrument cluster – • Remove instrument panel. Release fasteners (1) and remove bezel (4) with lens (6). Removing speedometer, rev. counter, temperature gauge, and fuel gauge L Note: Note that fasteners are of different lengths and have different coatings. Make sure they are reinstalled in their original positions. • Release fasteners for contacts at rear of housing and remove the appropriate instrument.
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Removing and installing wiring harness – a – Remove left and right fairing side sections. ....................................................See Group 46 Remove upper section of fairing. 1 d Warning: Comply with safety precautions when handling or working with fuel. – a – – a – Remove fuel tank. ....................................................See Group 16 Remove the intake air pipe. Remove the air output duct from the right-hand radiator. ....................................................
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62.
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63 63 Lights Contents Page Technical Data ............................................................................................................................... 3 Removing and installing headlight Renewing bulbs .....................................................................................5 .............................................................................................................................5 Bulb for low-beam headlight/ high-beam headlight .....................
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63.
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63 Technical Data K 1200 LT Lights Headlight H7 tandem headlight with free-form reflector and manual beam throw adjustment Bulbs High (main) beam headlight H3 halogen bulb, 12 V 55 W, asymmetric, Low (dipped) beam headlight H7 halogen bulb, 12 V 55 W, asymmetric Parking light 12 V 5 W DIN 72 601 Standard designation W 10/5 Brake light/rear light 12 V 21/5 W DIN 72 601 Standard designation P 25-2 Flashing turn indicators 12 V 21 W DIN 72 601 Standard designation P 25-1 Number plate light 12 V
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63.
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1 2 3 KL630020 Removing and installing headlight – a • • Remove top section of fairing with headlight. ....................................................See Group 46 Release securing screws (arrows) for headlight on top section of fairing. Remove the headlight. Bulb for low-beam headlight/ high-beam headlight • Press retaining clip (3) down and remove the housing cover (1). L Note: Do not touch inside of reflector and glass of bulbs with bare hands.
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Rear lights High (main) beam headlight • Open side case on left or right, as appropriate. 1 2 KL630030 • • • • • Disconnect plug (1). Bend back the ground clip (2) of the bulb for high-beam headlight and remove the bulb holder. Use a screwdriver to press in the retaining lugs on left and right and disassemble the bulb holder. Remove the H3 bulb from its ring. Installation is the reverse of the removal procedure.
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Checking headlight beam angle, adjusting if necessary Vertical adjustment • Set suspension preload to “LOW” (turn counterclockwise). L Note: Make sure that the adjuster on the instrument-panel cover is at the “UP” position (turned counter-clockwise as far as it will go). • KLPD0080 If necessary, turn the adjuster on the instrumentpanel cover counter-clockwise as far as it will go. Setting for headlight beam angle adjuster ....... .-10 cm (-3.94 in) at a distance of 10 m (32.80 ft) Turned to left.....
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63.
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65 65 Radio and optional extras Contents Page Removing and installing speakers ......................................................................................3 Front speakers .................................................................................................................................3 Preparatory work .................................................................................................................................3 Treble speaker .............................
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65.
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65 2 3 4 1 5 6 8 7 KL620030 Removing and installing speakers Front speakers Preparatory work – Remove upper section of fairing. a ....................................................See Group 46 – Remove interior trim. Treble speaker • Carefully straighten retaining lugs (arrow) on speaker bezel (4) and remove treble speaker (2). Bass speaker Carefully lift bass speaker (5) clear of retaining plate (1). • Disconnect plug (6) and remove speaker.
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1 3 2 4 5 Rear speakers KL460161 Removing and installing radio/ cassette player Preparatory work – a Remove tank cover with the control unit for the radio. ....................................................See Group 46 KL650060 – • • • • • • Disengage retaining strap (6) from lower section of top case. Remove screws (arrows) and remove armrest (1) with speakers from top case. Disconnect contacts from speakers (2). Remove fasteners (4) and remove retainers (3).
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X 1 3 2 4 5 6 7 KL650090 • Disconnect plug (2) of radio control unit. Removing radio control unit • 10 Remove fasteners (1) and remove radio control unit from tank cover. 9 Removing radio/cassette player and wiring harness 8 L Note: Straighten the retaining lugs (arrow) before disconnecting round connector (4). • • Disconnect plugs (3, 4) from holder. Remove fasteners (5, 7) and remove trim panel (6).
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Removing and installing radio remote control unit Removing and installing aerial holder Removing and installing front radio remote control unit See Group 61, Removing and installing radio control unit Removing and installing rear radio remote control unit • a 5 Remove rear seat. ....................................................See Group 52 4 3 KL510010 e Caution: Cap (4) can be damaged as you attempt to remove it. • KL610390 • • • • a • Disconnect plug (arrow).
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Removing and installing temperature sensor on upper section of fairing L Note: The temperature sensor on the upper fairing measures the outside temperature for display by the onboard computer. KL510150 • • • Remove fasteners (arrows) and remove aerial holder. Installation is the reverse of the removal procedure: pay particular attention to the following. Prior to installation, clean contact faces of aerial holder and rear frame. 2 X Tightening torques: Aerial holder to rear frame ...................
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Removing and installing control unit of cruise-control system – a – 4 Remove left side section of fairing. ....................................................See Group 46 Remove upper section of fairing. 1 2 KL650010 • • • Disconnect plug (arrow). Remove screws (4) securing retaining plate to fairing bracket. Remove retaining plate with control unit for cruise control system. KL130011 • • Carefully pull Bowden cable at sleeve (1) and remove insert (2).