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2002 2003 2004 BMW K 1200 LT Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: K 1200 LT Model Variant: Touring Motorcycle Model Years Covered: 2002, 2003, 2004 👋 Introduction Market Position Market Segment: Premium Grand Tourer Motorcycle...
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SKU: 349838
2002 2003 2004 BMW K 1200 LT Service Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
K 1200 LT
Model Variant:
Touring Motorcycle
Model Years Covered:
2002, 2003, 2004
👋 Introduction
Market Position
Market Segment:
Premium Grand Tourer Motorcycle
Target Audience:
Motorcycle owners and independent repair shops specializing in BMW motorcycles.
Competitive Analysis
Competitors:
Honda Gold Wing, Harley-Davidson Electra Glide, Yamaha FJR1300.
Key Features Of Vehicle
Touring Capabilities:
Designed for long-distance comfort and luggage capacity.
Key Features Of Manual
Value Proposition:
Authoritative, factory-authorized repair and maintenance information for accurate and efficient servicing.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service and Repair Manual
Language:
English
Format:
Digital Download (PDF)
Page Count:
Detailed, extensive (typical for factory manuals of this era, often 500+ pages)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, assembly, tuning, diagnosis, lubrication, cooling, fuel injection, ignition systems.
Transmission:
Clutch operation, gearbox disassembly and reassembly, final drive, shaft drive maintenance.
Brakes:
ABS system (Integral ABS), brake fluid replacement, caliper service, disc inspection, hydraulic system diagnostics.
Electrical:
Wiring diagrams, component testing, battery, starter, alternator, lighting, instrumentation, electronic control units (ECU), diagnostic trouble codes (DTCs).
Chassis:
Frame inspection, steering head bearings, suspension (front and rear), wheel bearings, wheels, tires.
Bodywork:
Fairing removal and installation, body panel repair and replacement, seats, luggage systems (top case, panniers).
Procedures Included
Maintenance:
Routine service checks, oil and filter changes, spark plug replacement, air filter service, brake pad inspection, clutch adjustment, drive shaft lubrication.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation for all major systems.
Overhaul:
Complete engine, gearbox, and final drive overhaul procedures.
Special Tools:
Identification and usage of specialized BMW service tools.
Technical Depth
Depth Level:
Factory-level, comprehensive repair and diagnostic information.
Diagnostic Coverage:
Detailed explanations of diagnostic trouble codes (DTCs) and their resolution, including sensor data interpretation.
Wiring Diagrams:
High-quality, detailed electrical wiring schematics for all systems.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes, text-searchable for quick information retrieval.
Printable:
Yes, designed for printing specific sections or the entire manual.
Print Quality
Image Resolution:
High resolution, suitable for clear reproduction of diagrams and images.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, four-cylinder, boxer engine (longitudinal crankshaft)
Displacement:
1171 cc (71.6 cu in)
Bore X Stroke:
76.5 mm x 64 mm (3.01 x 2.52 in)
Compression Ratio:
10.0:1
Performance
Horsepower:
Approx. 100 hp @ 7500 rpm (Note: Factory figures may vary slightly by region/spec)
Torque:
Approx. 115 Nm (85 lb-ft) @ 5250 rpm (Note: Factory figures may vary slightly by region/spec)
Fuel System
Fuel Induction:
Electronic fuel injection (EFI) with Bosch Motronic 2.4 system
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON + MON)/2 = 87 AKI
Fuel Tank Capacity:
24 liters (6.3 US gal)
🔧 Transmission
Standard
Transmission Type:
5-speed manual gearbox
Clutch:
Hydraulically operated single dry plate clutch
Final Drive:
Shaft drive with bevel gear
Features
Gear Ratios:
Specific gear ratios detailed within the manual.
Transmission Fluid Spec:
Refer to manual for specific type and capacity (typically SAE 75W-90 or similar for bevel gear).
📐 Dimensions
Exterior
Length:
Approx. 2430 mm (95.7 in)
Width:
Approx. 980 mm (38.6 in) at handlebars
Height:
Approx. 1430 mm (56.3 in) at windshield (adjustable)
Weights
Dry Weight:
Approx. 315 kg (694 lbs)
Gross Vehicle Weight Rating:
Approx. 510 kg (1124 lbs)
Payload Capacity:
Approx. 195 kg (430 lbs)
🛡️ Safety Features
Ratings
ABS Type:
Integral ABS (BMW's integrated anti-lock braking system)
Active Features
Braking System:
Dual front discs with four-piston calipers, single rear disc with two-piston caliper, linked braking (front and rear brake levers activate both brakes).
Lighting:
Halogen headlights, integrated turn signals, LED taillight.
Passive Features
Windscreen:
Electrically adjustable windscreen for rider comfort and protection.
Luggage Capacity:
Large capacity integrated panniers and optional top case.
💡 Technology Features
Infotainment
Audio System:
Integrated stereo system with speakers, CD player (on some models), and handlebar controls.
Cruise Control:
Standard electronic cruise control system.
Driver Assistance
ABS System:
Integral ABS for enhanced braking safety.
Connectivity
Diagnostic Port:
BMW's proprietary diagnostic connector for use with specialized diagnostic tools (covered in manual).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual, typically every 10,000 km (6,000 miles) or annually.
Major Service Interval:
Refer to manual, often around 20,000 km (12,000 miles) for valve checks, etc.
Fluid Specifications
Engine Oil Spec:
BMW Approved 5W-40 synthetic engine oil (refer to manual for exact BMW part number or equivalent).
Engine Oil Capacity:
Approx. 4.0 liters (4.2 US qt) with filter change (refer to manual).
Coolant Spec:
BMW Coolant/Antifreeze (blue) or equivalent quality ethylene glycol-based coolant with corrosion inhibitors (50/50 mix with distilled water).
Brake Fluid Spec:
DOT 4 specification brake fluid.
Transmission Fluid Spec:
Refer to manual for specific type and capacity (typically SAE 75W-90 gear oil for bevel gear).
Known Issues
Common Wear Items:
Clutch wear, brake pad wear, wheel bearings, steering head bearings.
Electrical Gremlins:
Occasional issues with ABS sensors, starter solenoids, or instrument cluster on older models; the manual will detail diagnostic procedures.
Fuel Pump:
Some models may experience fuel pump issues over time, troubleshooting covered in the manual.
📚 Vehicle History
Brand Heritage
Manufacturer:
Bayerische Motoren Werke AG (BMW)
Motorsport Legacy:
Long history of engineering excellence and innovation in motorcycles.
Model Evolution
K Series Introduction:
The K series was BMW's first major foray into inline-four cylinder motorcycles, initially launched in the early 1980s.
K 1200 Lt Development:
The K 1200 LT was developed as a premium touring motorcycle, building on the K 1100 LT and K 1200 RS platforms, focusing on rider comfort, integrated features, and long-distance capability.
Production
Production Period:
1998-2009 (with significant updates over its lifespan).
Manufacturing Location:
Berlin, Germany (BMW Motorrad plant)
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The K 1200 LT was widely praised in its time for its comfort, technology, and touring prowess, receiving positive reviews from major motorcycle publications.
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