BMW K1200 K1200LT 2003 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: K1200LT Year: 2003 Codes Chassis Code: K589 👋 Introduction Market Position Segment: Luxury Touring Motorcycle Target Audience: Touring enthusiasts seeking comfort, features, and...

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Type: Motorcycle

Vendor:

Sku: 433854

Tags: 2003 BMW Cars K1200 K1200LT Misc Motorcycle

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

K1200LT

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Luxury Touring Motorcycle

Target Audience:

Touring enthusiasts seeking comfort, features, and performance for long-distance riding.

Competitive Analysis

Competitors:

Honda Gold Wing, Harley-Davidson Electra Glide, Yamaha Royal Star Venture, Kawasaki Voyager.

Key Features

Design Philosophy:

BMW's emphasis on engineering excellence, rider comfort, and integrated technology for grand touring.

Model Distinction:

Known for its powerful engine, advanced features for its time, and exceptional comfort for rider and passenger on long journeys.

📋 Manual Details

Coverage Areas

Coverage:

Complete service, repair, diagnostics, and maintenance for the BMW K1200LT 2003 model.

Page Count

Page Count:

Extensive (typically 500+ pages for comprehensive manuals of this type, exact count not specified in product info)

Manual Type

Manual Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Likely PDF, Digital Download (typical for workshop manuals of this nature)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, inspection, troubleshooting, cylinder head, pistons, crankshaft, camshafts, valve train, oil system.

Fuel System:

Fuel injection system (EFI), fuel pump, injectors, fuel lines, fuel tank, throttle body, sensors (TPS, MAP, IAT), emissions control.

Ignition System:

Ignition coils, spark plugs, ECU control, timing.

Cooling System:

Radiator, coolant pump, thermostat, hoses, fan, coolant specifications.

Transmission:

Clutch operation and adjustment, gearbox internals, shift mechanism, transmission fluid specifications and change intervals.

Drivetrain:

Shaft drive system, final drive unit, driveshaft, universal joints, lubrication.

Brakes System:

Hydraulic brake system, ABS (Anti-lock Braking System), brake fluid specifications, caliper maintenance, rotor inspection, brake line replacement, bleeding procedures.

Suspension System:

Front forks (telescopic, possibly with electronic adjustment), rear shock absorber, linkage, spring rates, damping adjustments, fluid specifications for forks.

Steering System:

Handlebar assembly, steering head bearings, steering stem, adjustments, lubrication.

Electrical System:

Battery, charging system (alternator/generator), starter motor, lighting (headlight, taillight, turn signals), wiring diagrams, fuses, relays, ECU, diagnostics (OBD).

Bodywork And Trim:

Fairings, body panels, seat assembly, luggage systems (top case, saddlebags), instrumentation, mirrors, windshield adjustment/replacement.

Chassis And Frame:

Frame inspection, swingarm, wheel bearings, alignment, torque specifications for fasteners.

Diagnostics

Diagnostic Troubleshooting:

Systematic diagnostic procedures for common faults and error codes, using specialized tools (if applicable).

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, chain/shaft drive lubrication and adjustment, brake fluid flush, coolant flush.

Major Repairs:

Engine rebuilds, transmission overhaul, suspension component replacement, electrical system repairs, bodywork refinishing.

Troubleshooting Guides:

Step-by-step guides to identify and resolve specific performance issues and malfunctions.

Electrical Troubleshooting:

Schematic interpretation, testing of sensors, actuators, and wiring harnesses.

Technical Depth

Depth:

Comprehensive coverage suitable for professional mechanics and advanced DIY enthusiasts, including detailed torque specifications, tolerances, and diagnostic procedures.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format) - Assumed for ease of distribution and searchability.

Searchability:

Likely text-searchable for quick access to information.

Print Quality

Print Quality:

Designed for clear reproduction in print, featuring legible diagrams and text.

Binding Type

Binding Type:

N/A (Digital Format) - If printed, typically spiral-bound or perfect-bound for workshop use.

Paper Type

Paper Type:

N/A (Digital Format) - If printed, would typically be on durable, matte-finish paper for workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder, 4-stroke

Displacement:

1171 cc

Bore X Stroke:

79 mm x 59 mm

Compression Ratio:

10.0:1

Valve Train:

DOHC (Double Overhead Camshaft), 4 valves per cylinder

Cooling System:

Liquid-cooled

Performance

Horsepower:

Approx. 98 hp @ 7500 rpm (specification varies slightly by region and tuning)

Torque:

Approx. 117 Nm (86 lb-ft) @ 5200 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with Bosch Motronic engine management.

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON+MON)/2)

Oil System

Oil Capacity:

Approx. 4.0 liters (4.2 US quarts) with filter change.

Recommended Oil Type:

API SG/SH/SJ, ACEA A2/A3, SAE 5W-40 or 10W-40 Synthetic Motorcycle Oil.

🔧 Transmission

Standard

Transmission Type:

5-speed manual gearbox with integral clutch.

Features

Clutch Type:

Hydraulically operated multi-plate wet clutch.

Final Drive:

Shaft drive

Fluid Specifications

Transmission Oil Type:

SAE 75W-90 GL-5 gear oil (BMW recommends specific grades, manual will detail).

Fluid Capacity

Transmission Oil Capacity:

Approximately 0.5 liters (0.53 US quarts).

📐 Dimensions

Exterior

Length:

Approx. 2430 mm (95.7 in)

Width:

Approx. 960 mm (37.8 in) at handlebars

Height:

Approx. 1580 mm (62.2 in) at windshield

Weights

Dry Weight:

Approx. 330 kg (728 lbs)

Gross Vehicle Weight Rating:

Approx. 540 kg (1190 lbs)

Wheelbase

Wheelbase:

Approx. 1629 mm (64.1 in)

Seat Height

Seat Height:

Approx. 790 mm (31.1 in)

🛡️ Safety Features

Ratings

Integral ABS (often BMW's EVO ABS system).

Active Features

Braking System:

Dual front disc brakes, single rear disc brake. ABS system for enhanced control.

Lighting:

Halogen headlight, LED taillight, integrated turn signals.

Passive Features

Frame Design:

Sturdy aluminum frame providing rigidity and stability.

Wind Protection:

Large aerodynamic fairing and adjustable windshield for rider comfort and protection.

💡 Technology Features

Infotainment

Audio System:

Integrated audio system with AM/FM radio, CD player, and speakers (often with fairing-mounted controls).

Cruise Control:

Standard electronic cruise control for enhanced touring comfort.

Driver Assistance

Integral ABS for improved braking safety, often with a linked brake feel.

Connectivity

Diagnostic Interface:

On-board diagnostics (OBD) capabilities with specific BMW connectors and diagnostic software, detailed in the manual.

Comfort Features

Heated Grips Seats:

Typically equipped with heated grips and heated seats for rider and passenger.

Electric Windshield:

Power-adjustable windshield for optimal rider comfort in varying conditions.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 10,000 km (6,000 miles) or annually, whichever comes first. Check manual for specifics.

Air Filter Replacement:

Inspect every 20,000 km (12,000 miles), replace as needed or at major service intervals. Consult manual for exact schedule.

Spark Plug Replacement:

Typically every 20,000 km (12,000 miles). Check manual for specific plug type and gap.

Brake Fluid Flush:

Every 2 years or as per manual recommendation.

Coolant Change:

Every 2-4 years or as specified in the manual.

Fluid Specifications

Brake Fluid Type:

DOT 4 (or DOT 4 LV for ABS systems, verify in manual).

Coolant Type:

BMWapproved ethylene glycol-based coolant, typically a blue or green mixture (check manual for exact BMW specification).

Known Issues

Fuel Pump Reliability:

Some earlier K-series models experienced occasional fuel pump issues. Regular checks and replacement if symptoms arise.

Rear Shock ABSorber:

As with many touring bikes, the rear shock absorber may wear over time, affecting ride quality. Manual will cover inspection and replacement procedures.

Electrical Connections:

Corrosion or loose connections in electrical components can lead to intermittent issues. Manual provides wiring diagrams for troubleshooting.

Clutch Actuator:

Potential for wear or leaks in the hydraulic clutch actuator. Manual details inspection and servicing.

📚 Vehicle History

Brand Heritage

Manufacturer:

Bayerische Motoren Werke AG (BMW)

Heritage:

BMW has a long and storied history in motorcycle manufacturing, known for its engineering prowess and innovative designs dating back to the early 20th century.

Model Evolution

K Series Introduction:

The K-series, introduced in the early 1980s, marked BMW's significant foray into multi-cylinder, liquid-cooled engines, breaking from their traditional boxer-twin designs.

K1200Lt Development:

The K1200LT was developed as BMW's flagship luxury touring motorcycle, building upon the K1100LT and K1200LT platforms with enhanced features, power, and comfort.

Production

Production Period:

The K1200LT model range was produced from 1997 to 2009, with significant updates throughout its lifecycle.

Manufacturing Location:

Germany

🏆 Awards & Recognition

Recognitions

Category:

Luxury Touring Motorcycle Segment

Recognition Type:

Consistently rated highly by motorcycle publications and owners for its comfort, performance, and touring capability during its production run.

Ratings

Overall Owner Satisfaction:

Generally high owner satisfaction due to its robust build and touring features, despite potential maintenance needs common to complex luxury vehicles.