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BMW K1200LT K 1200 LT 2002 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: K1200LT Model Designation: K 1200 LT Year: 2002 Generation Generation Code: 1st Generation K1200LT Codes Chassis Code: K589 👋 Introduction Market Position Market...
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🏷️ Basic Information
Identification
Make:
BMW
Model:
K1200LT
Model Designation:
K 1200 LT
Year:
2002
Generation
Generation Code:
1st Generation K1200LT
Codes
Chassis Code:
K589
👋 Introduction
Market Position
Market Segment:
Luxury Grand Tourer Motorcycle
Target Audience:
Touring enthusiasts seeking comfort, performance, and long-distance capability, as well as owners and technicians performing maintenance and repairs.
Competitive Analysis
Key Competitors:
Honda Gold Wing, Harley-Davidson Electra Glide, Yamaha Royal Star Venture
Key Features
Unique Selling Points:
Long-distance comfort, sophisticated technology for its era, BMW's renowned engineering, powerful inline-four engine, integrated luggage, reverse gear (on some models/years).
Manual Value Proposition:
Provides the complete, authoritative technical documentation necessary for maintaining and repairing the K1200LT to factory standards, ensuring optimal performance and longevity.
📋 Manual Details
Coverage Areas
Systems Covered:
Engine, Fuel System, Ignition, Clutch, Transmission, Final Drive, Suspension, Brakes, Electrical System, Bodywork, Chassis, Diagnostics, Troubleshooting, Maintenance
Page Count
Page Count Estimated:
Hundreds of pages
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, inspection, and reassembly procedures for the inline four-cylinder engine, including valve timing, piston and cylinder inspection, crankshaft and connecting rod checks.
Fuel System:
Comprehensive coverage of the fuel injection system, including fuel pump diagnosis, injector testing, throttle body calibration, and evaporative emission control system.
Ignition System:
Detailed information on the electronic ignition system, including ignition coil testing, spark plug specifications, and troubleshooting ignition timing issues.
Clutch System:
Procedures for clutch inspection, adjustment, and replacement of clutch components for the hydraulic clutch system.
Transmission And Drivetrain:
Detailed instructions for transmission disassembly, gear inspection, shift mechanism repair, and final drive unit maintenance, including shaft and bearing checks.
Suspension System:
Front and rear suspension component inspection, adjustment, and repair, including fork seal replacement, shock absorber servicing, and linkage checks.
Brake System:
Detailed procedures for brake caliper overhaul, master cylinder inspection, ABS system diagnostics and troubleshooting, fluid flushing, and pad/rotor replacement.
Electrical System:
Extensive wiring diagrams, component testing procedures for starter motor, alternator, battery, lighting systems, instrument cluster, and electronic control units (ECU).
Bodywork And Frame:
Procedures for fairing removal and installation, seat adjustments, luggage system maintenance, and minor body panel repair.
Chassis And Steering:
Headstock bearing inspection and replacement, steering alignment checks, and wheel bearing maintenance.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain/drive shaft lubrication, brake fluid checks, tire pressure adjustments, and coolant level checks.
Troubleshooting Diagnostics:
Systematic diagnostic charts and procedures for identifying and resolving common and uncommon mechanical and electrical issues, including fault code interpretation.
Repair Rebuild:
Step-by-step instructions for component repair and complete system rebuilds, from engine internals to suspension linkages and electrical components.
Adjustment Calibration:
Procedures for adjusting clutch, throttle cables, suspension settings, and calibrating electronic systems like ABS and fuel injection.
Component Replacement:
Detailed guides for replacing wear items such as brake pads, tires, batteries, filters, and more specialized components like wheel bearings and drive shaft U-joints.
Technical Depth
Depth Level:
Comprehensive, factory-level technical information suitable for professional mechanics and advanced DIY enthusiasts.
Diagnostic Tools:
Includes information on specialized tools and diagnostic equipment required for specific procedures and fault finding.
Torque Specifications:
Detailed torque specifications for all fasteners throughout the motorcycle, crucial for proper assembly and safety.
Clearances Tolerances:
Essential service limits and tolerances for critical engine and drivetrain components to ensure proper operation and longevity.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval.
Print Quality
Printability:
Printable, allowing for individual page printing or complete manual output.
Binding Type
Binding Type For Print:
Not applicable (digital download), but designed for standard binding methods (e.g., comb, spiral, binder).
Paper Type
Paper Type For Print:
Not applicable (digital download), but typical recommendations would be durable, high-quality paper suitable for workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, inline four-cylinder
Displacement:
1171 cc (71.6 cu in)
Bore X Stroke:
78.8 mm x 61.8 mm
Compression Ratio:
10.0:1
Valvetrain:
DOHC, 4 valves per cylinder
Performance
Horsepower Max:
100 hp (74 kW) at 6750 rpm (approximate)
Torque Max:
115 Nm (85 lb-ft) at 5250 rpm (approximate)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Bosch Motronic MA 2.4
Fuel Type:
Unleaded Premium Gasoline (95 RON recommended)
Ignition
Ignition System:
Electronic ignition with dual spark plugs per cylinder
Cooling System
Cooling Method:
Liquid-cooled
Lubrication
Oil Capacity With Filter:
4.5 Liters (4.8 US qt)
Oil Type Recommended:
SAE 20W-40 or 20W-50 Motorcycle Oil (API SG or higher)
🔧 Transmission
Standard
Transmission Type:
5-speed manual
Clutch Type:
Hydraulic, multi-disc wet clutch
Final Drive:
Shaft drive
Features
Reverse Gear:
Electric reverse gear (standard on most K1200LT models)
Maintenance
Transmission Oil Type:
BMW Special Gear Oil (GL-5, SAE 75W-90)
Transmission Oil Capacity:
0.3 Liters (0.32 US qt)
📐 Dimensions
Exterior
Length:
2400 mm (94.5 in)
Width:
970 mm (38.2 in)
Height:
1430 mm (56.3 in) (seat height adjustable)
Wheelbase:
1625 mm (64.0 in)
Weights
Dry Weight Estimated:
337 kg (743 lbs)
Gross Vehicle Weight Rating:
570 kg (1257 lbs)
Fuel Tank Capacity:
21 Liters (5.5 US gal), including 3.5L reserve
Chassis And Suspension
Front Suspension:
BMW Telelever
Rear Suspension:
Paralever single-sided swingarm with central spring strut
Front Wheel Travel:
115 mm (4.5 in)
Rear Wheel Travel:
130 mm (5.1 in)
Wheels And Tires
Front Tire Size:
120/70 ZR17
Rear Tire Size:
170/80 ZR15
Front Wheel Type:
Cast aluminum alloy
Rear Wheel Type:
Cast aluminum alloy, single-sided swingarm
Wheelbase Bolt Pattern:
5 x 112 mm (typical for BMW automobiles, but specific for motorcycle hubs)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Motorcycle safety ratings are not typically standardized in the same way as automobiles. Focus is on engineering and rider aids.
Active Features
ABS System:
BMW Integral ABS (optional on some models, standard on later ones; includes linked braking)
Linked Braking:
Brake lever actuates both front and rear brakes (with ABS integration)
Passive Features
Lighting System:
Halogen headlights, integrated turn signals, rear brake light, and running lights.
Ergonomics:
Designed for rider comfort and control over long distances, contributing to reduced fatigue.
Wind Protection:
Full fairing and adjustable windshield provide significant wind and weather protection.
💡 Technology Features
Infotainment
Audio System:
Integrated stereo radio and cassette player (later models offered CD changer option).
Cruise Control:
Electronic cruise control system
Instrumentation:
Analog tachometer and speedometer, digital multi-function display (clock, temperature, gear indicator, fault codes).
Driver Assistance
ABS:
Integral Anti-lock Braking System (optional/standard depending on market and build date)
Connectivity
Diagnostic Interface:
On-board diagnostics (OBD) for fault code retrieval and system analysis.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 km (6,000 miles) or annually, whichever comes first.
Valve Check Interval:
Every 20,000 km (12,000 miles)
Coolant Flush Interval:
Every 2 years
Brake Fluid Flush Interval:
Every 2 years
Fluid Specifications
Coolant Type:
BMW approved silicate-free antifreeze (ethylene glycol based)
Brake Fluid Type:
DOT 4 (for ABS and non-ABS systems)
Clutch Fluid Type:
DOT 4 (shared with brake system)
Known Issues
Common Wear Items:
Clutch slave cylinder seals, water pump seals, fork seals, wheel bearings.
Electrical Concerns:
Some owners have reported issues with the ABS modulator, starter solenoids, and general electrical connections due to vibration and age.
Engine Specific Notes:
Regular valve adjustments and proper coolant levels are crucial for longevity. The engine is robust but requires diligent maintenance.
Fuel System Notes:
Keep fuel injectors clean and use high-quality fuel to prevent performance issues. Check fuel pump operation as per manual procedures.
📚 Vehicle History
Brand Heritage
Brand History:
BMW Motorrad, a division of Bayerische Motoren Werke AG, has a long and distinguished history in motorcycle design and manufacturing, dating back to the 1920s.
Model Evolution
K Series Introduction:
The K series, introduced in the early 1980s, marked BMW's foray into multi-cylinder, fuel-injected motorcycles, evolving from inline-fours to inline-threes and inline-sixes.
K1200Lt Development:
The K1200LT succeeded the K1100LT, representing BMW's flagship touring motorcycle, emphasizing comfort, technology, and performance for extended journeys.
Production
Production Period K1200Lt:
1997-2008 (with significant updates and variations between model years)
Manufacturing Location:
Berlin, Germany (Spandau plant)
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The K1200LT was widely praised for its comfort and touring capabilities, earning it a reputation as a premier grand tourer in its class during its production run.
Ratings
Owner Satisfaction:
Generally high owner satisfaction for long-distance comfort and reliability when properly maintained.
Certifications
Emission Standards:
Meets relevant emissions standards for its production year; manual will detail specific catalytic converter and emissions control system maintenance.