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1999-2003 BMW K1200LT (K 1200 LT) Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: K1200LT Model Nickname: K 1200 LT Year Range: 1999-2003 Codes Chassis Code: K589 👋 Introduction Market Position Segment: Luxury Touring Motorcycle Target Market:...
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Type: Motorcycle
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Sku: 488502
1999-2003 BMW K1200LT (K 1200 LT) Repair Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
K1200LT
Model Nickname:
K 1200 LT
Year Range:
1999-2003
Codes
Chassis Code:
K589
👋 Introduction
Market Position
Segment:
Luxury Touring Motorcycle
Target Market:
Long-distance touring, comfort-focused riders.
Competitive Analysis
Key Competitors:
Honda Gold Wing, Harley-Davidson Electra Glide, Yamaha Royal Star Venture.
Key Features
Distinctive Features:
Four-cylinder Boxer engine, shaft drive, extensive fairings, integrated luggage, optional ABS, cruise control, electric windscreen, heated grips/seat.
Manual Purpose
Value Proposition:
Provides essential factory-documented information for maintaining, troubleshooting, and repairing the K1200LT, ensuring optimal performance and longevity.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Manual / Repair Manual
Language:
English
Format:
Digital Download (PDF)
Page Count Estimate:
~700-900 pages (typical for comprehensive FSMs of this era)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of the K1200LT's four-cylinder Boxer engine, including cylinder heads, pistons, crankshaft, camshafts, valve train, lubrication system, and cooling system.
Fuel System:
Detailed procedures for fuel injection system maintenance, troubleshooting, and repair, including fuel pump, injectors, throttle bodies, fuel pressure regulator, and related sensors.
Ignition System:
Diagnostic and repair information for the electronic ignition system, including coil packs, spark plugs, and control modules.
Transmission Drivetrain:
Service and repair of the gearbox (sequential shifting), clutch system, and final drive (shaft drive), including lubrication and component replacement.
Braking System:
Comprehensive coverage of the Integral ABS braking system, including brake fluid replacement, caliper service, rotor inspection, ABS modulator troubleshooting, and hydraulic line maintenance.
Suspension Steering:
Detailed maintenance and repair for the front Telelever suspension and rear Monolever (Paralever) single-sided swingarm, including shock absorber servicing, fork seal replacement, and steering head bearing adjustments.
Electrical System:
Extensive information on the motorcycle's electrical system, including wiring diagrams, component testing, troubleshooting for lighting, charging system (alternator, regulator/rectifier), starter motor, battery, and instrument cluster.
Bodywork Fairings:
Instructions for the removal, installation, and repair of fairings, body panels, luggage systems (touring cases), windscreen, and seat assembly.
Chassis Frame:
Inspection and maintenance of the motorcycle's frame, subframe, and related structural components.
Comfort Features:
Maintenance and troubleshooting of features like heated grips, heated seats, cruise control, and power windscreen adjustments.
Procedures Included
Scheduled Maintenance:
Detailed maintenance schedules and procedures for all intervals, including oil changes, filter replacements, spark plug changes, and brake fluid flushes.
Troubleshooting Diagnostics:
Systematic diagnostic procedures and flowcharts for identifying and resolving common and complex issues across all motorcycle systems.
Component Repair Rebuild:
Step-by-step instructions for repairing and rebuilding major components, including engine internals, transmission, suspension units, and electrical modules.
Technical Specifications Data:
Comprehensive technical data, including torque specifications, clearances, fluid capacities, electrical resistances, and diagnostic trouble codes (DTCs).
Wiring Diagrams:
Full-color, detailed electrical wiring diagrams for all motorcycle circuits, enabling precise diagnosis and repair of electrical faults.
Special Tools Procedures:
Identification and usage instructions for specialized tools required for specific repair or maintenance tasks.
Technical Depth
Depth Of Coverage:
Factory-level detail covering routine maintenance, diagnostics, component-level repair, and full system overhauls.
Target Audience:
Professional motorcycle technicians and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Searchability:
Text-searchable for quick information retrieval.
Print Quality
Resolution:
High-resolution scans for clear text and diagrams.
Color Support:
Supports color printing, particularly for wiring diagrams and illustrated procedures.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Type:
Four-cylinder, four-stroke, Boxer engine
Displacement:
1171 cc (71.6 cu in)
Bore X Stroke:
77.6 mm x 64 mm (3.06 x 2.52 in)
Compression Ratio:
10.0:1
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower Hp:
100 hp (75 kW) @ 6750 rpm
Torque Lb Ft:
90 lb-ft (122 Nm) @ 4750 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - Bosch Motronic MA 2.4
Fuel Type:
Unleaded gasoline (95 RON / 91 AKI recommended)
Cooling System
Type:
Liquid-cooled
Lubrication System
Oil Capacity Quarts:
Approx. 4.0 quarts (3.8 liters)
Oil Type:
SAE 20W-40 Motorcycle Oil (refer to manual for exact specifications)
🔧 Transmission
Standard
Type:
5-speed sequential gearbox
Clutch Type:
Hydraulically actuated single dry plate clutch
Optional
Reverse Gear:
Electric reverse gear (standard on most models)
Features
Drive Type:
Shaft drive
Final Drive Ratio:
1:3.15
📐 Dimensions
Exterior
Length Mm:
Approx. 2570 mm (101.2 in)
Width Mm:
Approx. 1000 mm (39.4 in) (including mirrors)
Height Mm:
Approx. 1610 mm (63.4 in) (windscreen top)
Wheelbase Mm:
Approx. 1630 mm (64.2 in)
Weights
Dry Weight Kg:
Approx. 322 kg (710 lbs)
Wet Weight Kg:
Approx. 343 kg (756 lbs) (fully fueled)
Gross Vehicle Weight Rating Kg:
Approx. 515 kg (1135 lbs)
Fuel Capacity
Tank Capacity Liters:
24 liters (6.3 US gallons)
🛡️ Safety Features
Ratings
ABS Availability:
Integral ABS often optional or standard on later models
Active Features
Braking System Design:
Integral ABS system with linked front and rear braking actuation.
Lighting:
Halogen headlights, LED taillight, indicator lights.
Passive Features
Frame Construction:
Aluminum twin-spar frame for rigidity.
Aerodynamics:
Full fairing and windscreen designed for rider protection and comfort.
💡 Technology Features
Infotainment
Audio System:
Integrated audio system with radio, cassette player, and often CD changer compatibility (depending on options).
Cruise Control:
Electronic cruise control system for highway comfort.
Driver Assistance
ABS:
BMW Integral Anti-lock Braking System (ABS), a significant safety feature for its time.
Connectivity
Diagnostic Interface:
On-board diagnostics, though the manual is key for interpreting codes and performing advanced diagnostics.
Comfort Features
Heated Components:
Optional heated grips and heated rider/pillion seats.
Windscreen Adjustment:
Electrically adjustable windscreen for optimal wind protection.
🔧 Maintenance
Service Intervals
Oil Change Interval Km:
10,000 km (6,000 miles) or annually, whichever comes first.
Filter Replacement Interval Km:
Oil filter: every oil change. Air filter: typically 20,000-30,000 km (12,000-18,000 miles).
Valve Adjustment Interval Km:
20,000 km (12,000 miles)
Brake Fluid Change Interval Years:
Every 2 years
Fluid Specifications
Engine Oil Spec:
BMW Motorrad recommends SAE 20W-40 motorcycle oil API SG/SH or higher. Check manual for specific ACEA ratings.
Coolant Type:
BMW approved coolant (ethylene glycol-based) mixed with distilled water (50/50).
Brake Fluid Type:
DOT 4 brake fluid (for Integral ABS system).
Final Drive Oil Type:
SAE 80W-90 hypoid gear oil.
Known Issues
Electrical Gremlins:
Intermittent electrical issues, particularly related to the CAN-bus system (though less prevalent in this generation), wiring harness chafing, and sensor failures. The manual is crucial for diagnosing these.
Fuel Pump Reliability:
Occasional reports of fuel pump failure, especially at higher mileage.
Suspension Leaks:
Potential for fork seal leaks or rear shock absorber issues over time, requiring specialized seals and oil.
Throttle Body Synchronization:
Essential for smooth engine operation; requires precise synchronization of the throttle bodies.
📚 Vehicle History
Brand Heritage
Bmw Motorcycle Division:
BMW's long-standing reputation for engineering excellence, innovation, and touring motorcycles.
Model Evolution
K Series Introduction:
The K-series, introduced in the early 1980s, revolutionized motorcycle design with its inline-four and later boxer engines, and monocoque frames.
K1100Lt Predecessor:
The K1200LT evolved from the K1100LT, offering increased displacement and enhanced touring features.
K1200Gt Relation:
Shared its engine and some chassis elements with the K1200GT sport-touring variant.
Production
Production Period:
1999-2009 (this manual covers the initial generation 1999-2003)
Manufacturing Location:
Berlin, Germany (BMW Motorrad factory)
🏆 Awards & Recognition
Recognitions
Industry Reviews:
Consistently praised in period reviews for its comfort, performance, and touring capability.
Ratings
Long Distance Aptitude:
Regarded as one of the premier long-distance touring motorcycles of its era.
Certifications
Manual Authenticity:
Represents genuine factory service documentation.
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