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BMW K1200LT K 1200 LT 2004 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: BMW Model: K1200LT Model Year: 2004 Generation Generation Designation: K1200LT (2nd Generation) Codes Chassis Code: K589 👋 Introduction Market Position Vehicle Segment: Luxury Grand Tourer...
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🏷️ Basic Information
Identification
Make:
BMW
Model:
K1200LT
Model Year:
2004
Generation
Generation Designation:
K1200LT (2nd Generation)
Codes
Chassis Code:
K589
👋 Introduction
Market Position
Vehicle Segment:
Luxury Grand Tourer (GT) Motorcycle
Target Audience:
Touring riders seeking comfort, technology, and long-distance capability.
Competitive Analysis
Key Competitors Era:
Honda Gold Wing, Harley-Davidson Electra Glide Ultra Classic, Kawasaki Voyager.
Key Features
Aerodynamics:
Extensive fairings and integrated windshield for rider protection and comfort.
Ergonomics:
Comfortable seating, adjustable ergonomics, and integrated luggage for long-distance touring.
Powertrain Layout:
Longitudinal inline-four engine with shaft drive.
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete factory service and repair
Page Count
Estimated Page Count:
Hundreds (printable in entirety or select pages)
Manual Type
Manual Classification:
Factory Service Manual / Workshop Manual / Repair Manual
Language
Language Provided:
English
Format
Delivery Format:
Digital Download (PDF)
File Format:
PDF (Portable Document Format)
Searchability:
Text-searchable PDF for quick information retrieval.
Print Quality:
High-resolution graphics and text suitable for printing.
Binding Type
Digital Binding:
N/A (Digital Download)
Paper Type
Digital Paper Type:
N/A (Digital Download)
📖 Manual Coverage
Systems Covered
Engine System:
Full engine diagnosis, repair, overhaul, including fuel injection, ignition, lubrication, cooling, and exhaust systems.
Transmission System:
Complete transmission service, repair, clutch operation, and final drive.
Chassis And Suspension:
Front and rear suspension (including BMW Paralever and Duolever), steering system, wheel bearings, and hub assemblies.
Braking System:
ABS system (Integral ABS), brake fluid service, caliper overhaul, disc replacement, and hydraulic lines.
Electrical System:
Comprehensive wiring diagrams, diagnostic procedures for ECU, sensor inputs/outputs, lighting, charging system, starter, instrumentation, and accessory circuits.
Fuel System:
Fuel pump, injectors, fuel tank, pressure regulation, and diagnostics.
Diagnostic Troubleshooting:
Step-by-step troubleshooting guides for common and uncommon faults, fault code identification, and diagnostic procedures.
Body And Fairings
Bodywork And Plastics:
Removal and installation of fairings, body panels, seat, luggage systems, and interior trim.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug service, brake fluid flush, coolant checks, valve clearance adjustments, and lubrication points.
Major Repairs:
Engine rebuild, transmission overhaul, suspension component replacement, electrical system diagnosis and repair, brake system overhaul.
Component Overhaul:
Detailed procedures for disassembling, inspecting, repairing, and reassembling major components like the engine, transmission, and suspension.
Electrical Diagnostics:
Testing of sensors, actuators, ECUs, and troubleshooting electrical faults using wiring diagrams and diagnostic tools.
Torque Specifications:
Comprehensive list of all critical torque values for fasteners across all systems.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostic procedures for electronic control units (ECU), sensor data analysis, and fault code interpretation.
Rebuild Procedures:
Full engine and transmission rebuild procedures with detailed diagrams and specifications.
Wiring Diagrams:
High-detail, system-specific wiring diagrams for electrical troubleshooting.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-four cylinder, four-stroke
Displacement:
1171 cc (71.4 cu in)
Bore X Stroke:
79 mm x 59 mm
Compression Ratio:
11.0:1
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower:
110 hp (82 kW) @ 7500 rpm (approximate, varies slightly by market)
Torque:
120 Nm (88.5 lb-ft) @ 5250 rpm (approximate, varies slightly by market)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with sequential port injection
Fuel Type:
Unleaded premium gasoline (95 RON / 91 AKI)
Fuel Capacity:
24 liters (6.3 US gal)
Cooling System
Cooling Method:
Liquid-cooled
Lubrication System
Oil Capacity:
4.2 liters (4.4 US qt) with filter change
Recommended Oil Grade:
SAE 5W-40 synthetic motorcycle oil (BMW recommends Castrol)
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh manual
Final Drive:
Shaft drive
Features
Clutch Type:
Hydraulically operated, multi-disc wet clutch
Transmission Oil Capacity:
Approximately 1.3 liters (1.4 US qt)
Recommended Transmission Oil:
API GL-5, SAE 75W-90 synthetic gear oil
📐 Dimensions
Exterior
Length:
2620 mm (103.1 in)
Width:
1020 mm (40.2 in) (at mirrors)
Height:
1630 mm (64.2 in) (at highest windshield position)
Wheelbase:
1626 mm (64.0 in)
Weights
Dry Weight:
322 kg (710 lbs)
Gross Vehicle Weight Rating:
510 kg (1124 lbs)
Maximum Payload:
188 kg (414 lbs)
Gvwr With Passenger And Luggage:
510 kg (1124 lbs)
Cargo
Top Case Capacity:
Approx. 55 liters, integrated passenger backrest
Saddlebag Capacity:
Approx. 32 liters per side
🛡️ Safety Features
Ratings
ABS System:
BMW Integral ABS (fully integrated, rider-adjustable)
Active Features
Lighting:
Halogen dual headlights, LED taillight, integrated turn signals.
Braking System Features:
Dual front discs with 4-piston calipers, single rear disc with 2-piston caliper, linked braking (Integral ABS).
Passive Features
Frame Construction:
Aluminum twin-spar frame with integral subframe for luggage capacity.
Ride By Wire:
Electronic throttle control (drive-by-wire) for smoother power delivery and cruise control integration.
💡 Technology Features
Infotainment
Audio System:
Integrated premium audio system with AM/FM radio, CD player, and provisions for auxiliary input.
Cruise Control:
Electronic cruise control system.
Heated Grips And Seats:
Standard heated grips for rider and passenger, heated seat for rider.
Driver Assistance
ABS:
BMW Integral ABS (Anti-lock Braking System), combining front and rear brakes into a single, electronically managed system.
Reverse Assist:
Electric reverse gear, operated via a button.
Connectivity
Diagnostic Interface:
On-board diagnostics (OBD) system, requiring specialized BMW diagnostic tools for full access, which this manual supports understanding.
Power Outlets:
12V accessory power outlets for charging devices.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 10,000 km (6,000 miles) or annually, whichever comes first.
Brake Fluid Flush:
Every 2 years.
Coolant Change:
Every 2 years.
Valve Clearance Check:
Every 20,000 km (12,000 miles).
Spark Plug Replacement:
Every 20,000 km (12,000 miles).
Fluid Specifications
Engine Oil Type:
BMW Longlife 04 (LL-04) compliant synthetic oil or equivalent, SAE 5W-40 is commonly recommended.
Brake Fluid Type:
DOT 4 (for Integral ABS system).
Coolant Type:
BMW Premium Coolant (ethylene glycol based) or equivalent, mixed 50/50 with distilled water.
Known Issues
Electrical Gremlins:
Can sometimes experience minor electrical glitches due to complex systems; manual helps diagnose.
Stiff Clutch Lever:
Hydraulic clutch system may require occasional bleeding or adjustment for optimal feel.
Final Drive Seals:
Occasional leakage from final drive seals, requiring replacement as per manual procedures.
Starter Motor Brushes:
Wear on starter motor brushes can occur over high mileage, manual covers inspection and replacement.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Germany
Brand Philosophy:
Engineering excellence, rider focus, innovation, and premium quality.
Model Evolution
K Series Heritage:
Successor to the K1100LT, part of BMW's long-standing K-series of horizontally opposed four-cylinder and inline-four motorcycles.
Generation Changes Vs Predecessor:
Increased displacement, updated styling, enhanced aerodynamics, improved suspension, and advanced electronics.
Production
Production Period:
The K1200LT was produced from 1999 to 2009.
Manufacturing Location:
Berlin, Germany
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Consistently praised for its touring comfort, advanced features, and the performance of its unique powertrain for its class.
Owner Satisfaction:
High owner satisfaction ratings, particularly among dedicated touring enthusiasts who value its long-distance capabilities and amenities.
Certifications
Manual Certification:
Official Factory Certified Service Manual.