BMWK1200LTRepairManual

BMWAGMotorcycleDivisionAfterSalesK1200LTRepairManualPublishedby:©BMWAGMotorcycleDivisionAfterSalesUX-VS-2Allrightsreserved.Nottobereprinted,translatedorduplicatedeitherwhollyorinpartwithoutpriorwrittenpermission.Errorsandomissionsexcepted;subjecttotechnicalamendment.ProducedinGermany7/99IntroductionThisrepairmanualwillhelpyoutoperformallthemainmaintenanceandrepairworkcorrectlyandefficient-ly.Ifitisconsultedregularlybyworkshoppersonnelitwillformausefuladditiontothetheoreticalandprac-ticalknowledgeacquiredattheBMWTrainingCentre.ItisacontributiontowardsachievingevenhigherServicequality.Anewissueofthisrepairmanualwillbepublishedifamendmentsoradditions(supplements)areneeded.AllinformationinbothtextandillustrationsreferstomotorcyclesinstandardconditionorwithgenuineBMWaccessoriesinstalled,andnottomotorcycleswhichhavebeenmodifiedinanywaytodepartfromthemanufacturer’sspecification.•Therepairmanualisstructuredinthelogicalsequenceoftheworktobeperformed:Removal,Disas-sembly,Repair,Assembly,Installation.•Theentirecontentsaredividedintoindividualchapters,correspondingtotheConstructionGroups.11.10ChapterPagenumberwithinchapterAnarrowsymbolfollowedbythechapterandpagenumbersisareferencetoanotherchapter,e.g.Ób............................................SeeGroup46•WorktobeperformedduringanInspectionisdescribedinGroup“00”.ThevariousinspectionroutinesarenumberedI,II,IIIandIV.Thisnumberingisrepeatedintheworkdescriptionswhichfollow,sothatworkcantakeplacewithoutinterruption.•UseoftheBMWspecialtoolsneededforcertaintasksisdescribedintheworkinstructions.Iftheneedarises,repairinstructionsarealsoissuedintheformofServiceInformation.Thisinformationisofcourseincorporatedintothenextissueoftherepairmanual.Wealsorecommend,asanadditionalsourceofinformation,theElectronicPartsCatalogue(ETC),whichcontainsclearandeasy-to-followillus-trations.Iftheworkdescribedhereisrestrictedtoaparticularequipmentspecification,forinstanceifaspecificop-tionalextra(OE)isfitted,thisisstatedinsquarebracketsatthestartoftheitemconcerned,e.g.[Withheat-edhandlebargrips].Pleaserefertothefollowingpagesaswellforadescriptionofothersymbolsusedandhowtoworkwithit.BMWAGMotorcycleDivisionAfterSalesPublishedby:BMWAGSparteMotorradAfterSalesUX-VS-2D-80788MünchenAllrightsreserved.Nottobereprinted,translatedorduplicatedeitherwhollyorinpartwithoutpriorwrittenpermission.Errorsandomissionsexcepted;subjecttotechnicalamendment.ProducedinGermanyUsageEachchapterstartswiththelistofcontents.ThelistofcontentsisfollowedbytheTechnicalDatatable.Chapter00“Maintenanceandgeneralinstructions”detailsthehandoverchecklistandlistsalltighteningtorquesandoperatingfluids.KeytosymbolsInthisWorkshopManualfortheK1200LTmodel,thefollowingsymbolsareused;theirmeaningsareex-plainedinthetable.SpecialinstructionsaimedatimprovingtheworkproceduresLNote:Specificinformationonoperating,inspectingandadjustingworkforthemotorcycleaswellasmaintenanceprocedures.eCaution:Instructionsandprecautionsspecificallyintendedtopreventdamagetothemotorcycle.Failuretocomplywiththemcouldinvalidatethewarranty.dCaution:Thissymbolstandsforprecautionsandmeasureswhichareessentialinordertoprotecttheriderorotherpersonsfrompossiblysevereorfatalinjury.ContentsHeadlinesfortheworkdescribedinthechapter...........................................withtherelevantpagenumberActivities•Activities•Thebulletsymbolmeansthatworkstepsaredescribedingreaterdetailunderanotherheadline–Precedingactivities–AlineindicatesworkstepsdescribedingreaterdetailunderanotherheadlineorinanotherchapterIftheterm“release”or“remove”isused:thefastener(e.g.screw)mustbeslackenedoffandtakenoutoracomponent(e.g.fuelrail)mustberemovedtotheextentthatothercomponentswhichitconceals(e.g.throttle-valverail)areaccessibleIftheterm“loosen”or“slacken”isused:thefastener(e.g.screw)mustonlybeslackenedoffbutnottakenoutXTighteningtorques:ValuesarestatediftheydifferfromDINEN24014orDIN912ISOindustrialstandards.00Maintenanceandgeneralinstructions00.111Motor11.112Engineelectrics12.113Fuelpreparationandcontrol13.116Fueltankandlines16.117Radiator17.118Exhaustsystem18.121Clutch21.123Gearbox23.131Frontfork31.132Steering32.1ContentsGroup/Chapter33Rearwheeldrive33.134Brakes34.136Wheelsandtyres36.146Frame46.151Equipment51.152Seat52.161Generalelectricalequipment61.162Instruments62.163Lights63.165Radioandoptionalextras65.1Group/ChapterOrderNo.01719799278UX-VS-2,01/99PrintedinGermanyCustomerLicenceplateNo.OrderNo.Mechanic’ssignatureBMWInspectionat1,000km(600miles)BMWServiceevery10,000km(6,000miles)BMWInspectionevery20,000km(12,000miles)BMWAnnualServiceReadoutthefaultmemorywiththeBMWMoDiTeCunitCheckthrottlecableplay,adjustifnecessaryChangeengineoilwhileatoperatingtemperatureIfthemotorcycleisriddenonlyforshortdistancesoratoutsidetemperaturesbelow0°C(32°F),thisworkmustbedoneevery3monthsoratleastevery3,000km(1,800miles)*)Changeoilingearboxwhileatoperatingtemperatureatleastevery2years*)every2yearsChangeoilinrearwheeldrivewhileatoperatingtemperatureatleastevery2years*)every2yearsExaminebrakepadsanddiscsforwear,replaceifnecessa