BMW K1200LT 1999 User Manual [ru]

Repair Manual

K 1200 LT

BMW AG Motorcycle Division

After Sales

Published by:	© BMW AG Motorcycle Division
	After Sales
	UX-VS-2

All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission.

Errors and omissions excepted; subject to technical amendment.

Produced in Germany 7/99

Introduction

This repair manual will help you to perform all the main maintenance and repair work correctly and efficiently. If it is consulted regularly by workshop personnel it will form a useful addition to the theoretical and practical knowledge acquired at the BMW Training Centre. It is a contribution towards achieving even higher Service quality.

A new issue of this repair manual will be published if amendments or additions (supplements) are needed.

All information in both text and illustrations refers to motorcycles in standard condition or with genuine BMW accessories installed, and not to motorcycles which have been modified in any way to depart from the manufacturer’s specification.

•The repair manual is structured in the logical sequence of the work to be performed: Removal, Disassembly, Repair, Assembly, Installation.

•The entire contents are divided into individual chapters, corresponding to the Construction Groups.

11 . 10

Chapter

Page number within chapter

An arrow symbol followed by the chapter and page numbers is a reference to another chapter, e.g. Ób ............................................See Group 46

•Work to be performed during an Inspection is described in Group “00”. The various inspection routines are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that work can take place without interruption.

•Use of the BMW special tools needed for certain tasks is described in the work instructions.

If the need arises, repair instructions are also issued in the form of Service Information. This information is of course incorporated into the next issue of the repair manual. We also recommend, as an additional source of information, the Electronic Parts Catalogue (ETC), which contains clear and easy-to-follow illustrations.

If the work described here is restricted to a particular equipment specification, for instance if a specific optional extra (OE) is fitted, this is stated in square brackets at the start of the item concerned, e.g. [With heated handlebar grips].

Please refer to the following pages as well for a description of other symbols used and how to work with it.

BMW AG Motorcycle Division

After Sales

Published by:	BMW AG Sparte Motorrad
	After Sales
	UX-VS-2
	D - 80788 München

All rights reserved. Not to be reprinted, translated or duplicated either wholly or in part without prior written permission.

Errors and omissions excepted; subject to technical amendment.

Produced in Germany

Usage

Each chapter starts with the list of contents.

The list of contents is followed by the Technical Data table.

Chapter 00 “Maintenance and general instructions” details the handover checklist and lists all tightening torques and operating fluids.

Key to symbols

In this Workshop Manual for the K 1200 LT model, the following symbols are used; their meanings are explained in the table.

Special instructions aimed at improving the work procedures

L Note:

Specific information on operating, inspecting and adjusting work for the motorcycle as well as maintenance procedures.

e Caution:

Instructions and precautions specifically intended to prevent damage to the motorcycle. Failure to comply with them could invalidate the warranty.

d Caution:

This symbol stands for precautions and measures which are essential in order to protect the rider or other persons from possibly severe or fatal injury.

Contents

Headlines for the work described in the chapter...........................................

with the relevant page number

Activities

•Activities

•The bullet symbol means that work steps are described in greater detail under another headline

–Preceding activities

–A line indicates work steps described in greater detail under another headline or in another chapter

If the term “release” or “remove” is used:

the fastener (e.g. screw) must be slackened off and taken out or

a component (e.g. fuel rail) must be removed to the extent that other components which it conceals (e.g. throttle-valve rail) are accessible

If the term “loosen” or “slacken” is used:

the fastener (e.g. screw) must only be slackened off but not taken out

X Tightening torques:

Values are stated if they differ from DIN EN 24 014 or DIN 912 ISO industrial standards.

Contents

Group / Chapter
00	Maintenance and general instructions	00.1
11	Motor	11.1
12	Engine electrics	12.1
13	Fuel preparation and control	13.1
16	Fuel tank and lines	16.1
17	Radiator	17.1
18	Exhaust system	18.1
21	Clutch	21.1
23	Gearbox	23.1
31	Front fork	31.1
32	Steering	32.1

Group / Chapter
33	Rear wheel drive	33.1
34	Brakes	34.1
36	Wheels and tyres	36.1
46	Frame	46.1
51	Equipment	51.1
52	Seat	52.1
61	General electrical equipment	61.1
62	Instruments	62.1
63	Lights	63.1
65	Radio and optional extras	65.1

BMW AG Motorcycle Division

Maintenance schedule

K 1200 LT

	Customer	Licence plate No.
	Order No.	Mechanic’s signature

Read out the fault memory with the BMW MoDiTeC unit

Check throttle cable play, adjust if necessary

Change engine oil while at operating temperature

If the motorcycle is ridden only for short distances or at outside temperatures below 0 °C (32 °F), this work must be done every 3 months or at least every 3,000 km (1,800 miles) *)

BMW Inspection at 1,000 km (600 miles)

BMW Service every 10,000 km (6,000 miles)

BMW Inspection every 20,000 km (12,000 miles)

BMW Annual Service

Change oil in gearbox while at operating temperature at least every 2 years *)

Change oil in rear wheel drive while at operating temperature at least every 2 years *)

Examine brake pads and discs for wear, replace if necessary *)

Check the front/rear brake fluid level

Check operation of brake system and freedom from leaks; repair/replace items if necessary *)

Replace the brake fluid at least once a year

Check clutch operating fluid level

Change clutch fluid

every 40,000 km (24,000 miles) or at least every 2 years *)

Replace fuel filter *)

generally every 40,000 km (24,000 miles), if the fuel is of poor quality, every 20,000 km (12,000 miles)

Check and top up, where necessary, coolant level and concentration

Replace the coolant at least every 2 years*)

Check battery acid level, if necessary add distilled water

Clean/grease battery terminals if necessary

Replace intake air cleaner element

If severe dirt and dust are encountered, replace the intake air cleaner every 10,000 km (6,000 miles) or even more frequently *)

Check function of side stand contact switch

Grease side stand bearing, check that the centre stand moves freely, and grease it if necessary *)

Check the steering damper

Check tightness of rear wheel studs

Check rear wheel bearing play by rocking wheel

Check swinging arm bearings (free of play), adjust if necessary *)

Clean the inductive sensor on the rear wheel every 40,000 km (24,000 miles) or at least every 2 years *)

Check valve clearances, adjust if necessary

Replace the lining of the chain tensioning rail and chain guide rail every 60,000 km (36,000 miles)*)

Replace spark plugs

Final inspection with road safety and functional check:

–Condition of tires and wheels, tyre pressure

–Clutch, gearshift mechanism, hand and foot brake, ABS, steering system

–Lighting and signalling equipment, telltale lights, instruments, horn

–Reversing aid, radio with remote contro, optional equipment fitted

–Trial run if necessary

*) Charged as an additional item

every 2 years

every 2 years

40,000

every 2 years

40,000

every 2 years

40,000

every 2 years

60,000

Order No. 01 71 9 799 278

UX-VS-2, 01/99

Printed in Germany

BMW AG Motorcycle Division

Pre-delivery check

K 1200 LT

Customer		Licence plate No.
Order No.		Mechanic’s signature

Check the shipping crate for damage

Unpacking the motorcycle

–	unpack
–	inspect for damage
–	check that delivery is complete	Motorcycle keys
		Top case lock cylinder
		Toolkit and helmet lock

Documentation

Top case (packed separately)

Optional extras

Installing remaining items on motorcycle

–Fit front wheel and mudguard

–Fit the mirror

–Fit the right-hand side footrest and passenger footrest plate

–Fit engine spoiler, reversing aid actuation, bumpers

–Install the top case

Fill and charge the battery (mark with charging date)

Check the front/rear brake fluid level

Check clutch fluid level

Check tyre pressures

Check rear wheel studs for tightness (note correct tightening torque)

Fit antenna, windshield

Checking and adjusting the motorcycle

–Check function of side stand contact switch

–Seat

–Top case

–Headlight, spring strut

Add fuel

Final inspection and function check

–Check engine oil when engine is cold

–Clutch, gearshift mechanism, reversing aid

–Lighting and signalling equipment, telltale lights, instruments

–Check radio for operation

–Hand brake and foot brake, ABS

–Check optional equipment for operation

CD player, on-board computer, cruise control

–Trial run if necessary

Confirm pre-delivery check in Service and Technical Booklet

Final cleaning

Motorcycle handed over on:

BMW

Pre-delivery check

Order No. 01 71 9 799 278

UX-VS-2, 01/99

Printed in Germany

00 Maintenance and general instructions

Tightening torques and Table of operating fluids Pre-delivery check

Maintenance

Contents	Page
Tightening torques ......................................................................................................................	7
Table of operating fluids .........................................................................................................	19

00.1

Contents - Pre-delivery check	Page
Overview: K1200LT packing materials ...........................................................................	21
Checking the shipping crate for damage .....................................................................	22
Damage discovered in Germany ............................................................................................	22
Damage discovered in importer markets ...........................................................................	22
Unpacking the motorcycle ....................................................................................................	23
Installing the front wheel .......................................................................................................	24
General instructions .................................................................................................................	26
Pushing the motorcycle onto a workshop platform .......................................................	26
Inspecting motorcycle for damage ..................................................................................	26
Checking that delivery is complete ..................................................................................	26
Installing remaining items on motorcycle ....................................................................	27
Installing the front mudguard ...................................................................................................	27
Installing the mirrors ....................................................................................................................	27
Installing the footrests .................................................................................................................	28
Installing the rear left footrest plate ....................................................................................................	28
Installing the rear right footrest and footrest plate .............................................................................	28
Installing the engine spoilers ...................................................................................................	29
Installing the reverser control ..................................................................................................	29
Installing the skirts ........................................................................................................................	29
Installing the top case .................................................................................................................	30
Additional instructions for moving the backrest .................................................................................	30
Filling and charging the battery .........................................................................................	31
Checking brake fluid level .....................................................................................................	32
Front brake .......................................................................................................................................	32
Rear brake ........................................................................................................................................	33
Checking clutch fluid level ....................................................................................................	34
Checking tyre pressures ........................................................................................................	34
Checking tightness of rear wheel studs ........................................................................	34
Installing the aerial ....................................................................................................................	34
Installing the windscreen .......................................................................................................	35

00.2

Contents - Pre-delivery check	Page
Installing the windscreen cover ..............................................................................................	35
Checking and adjusting the motorcycle ........................................................................	35
Checking the function of side stand contact switch .....................................................	35
Adjusting the seat .........................................................................................................................	35
Adjusting the top case ................................................................................................................	35
Checking headlight beam angle, adjusting if necessary .............................................	36
Vertical adjustment ............................................................................................................................	36
Lateral adjustment .............................................................................................................................	36
Final inspection and function check ...............................................................................	37
Final cleaning ................................................................................................................................	37

00.3

Contents - Maintenance	Page
Key to maintenance intervals ..............................................................................................	38
General instructions .................................................................................................................	39
Pushing the motorcycle onto a workshop platform .......................................................	39
High idle speed ..............................................................................................................................	39
Removing the aerial .....................................................................................................................	39
Reading the fault code memory with the MoDiTeC ................................................	40
(Inspections I, II, III and IV) .................................................................................................................	40
Checking throttle cable play, adjusting if necessary .............................................	40
(Inspections I and III) .........................................................................................................................	40
Models without cruise control .................................................................................................	40
Models with cruise control ........................................................................................................	40
Throttle-opener cable, throttle-closer cable ......................................................................................	40
Cruise-control system cable ..............................................................................................................	41
Turning the throttle twist grip relative to the throttle valve shaft ..............................	41
Cruise control system does not switch off .........................................................................................	41
Cruise control system cannot be set, or continually shuts down .......................................................	41
Changing engine oil, replacing oil filter element ......................................................	42
(Inspections I, II, III and IV) .................................................................................................................	42
Changing gearbox oil ...............................................................................................................	43
Change the gearbox oil every two years at the latest .........................................................................	43
(Inspection III) ....................................................................................................................................	43
Changing the oil in the rear wheel drive ........................................................................	44
Change the oil in the rear wheel drive every two years at the latest ...................................................	44
(Inspections I and III) .........................................................................................................................	44
Brake pads/brake discs ..........................................................................................................	45
Checking brake pads and discs for wear and replacing if necessary .................................................	45
(Inspections II and III) .........................................................................................................................	45
Checking brake pads for wear ................................................................................................	45
Front brake pads ...............................................................................................................................	45
Rear brake pads ................................................................................................................................	45
Replacing brake pads .................................................................................................................	46
Front brake ........................................................................................................................................	46
Rear brake ........................................................................................................................................	47
Checking the brake discs .........................................................................................................	48

00.4

Contents - Maintenance	Page
Checking the front/rear brake fluid level ......................................................................	48
(Inspections I, II and III) ......................................................................................................................	48
Checking the front brake fluid level ......................................................................................	48
Checking the fluid level with brake fluid
reservoir open ...................................................................................................................................	49
Checking the rear brake fluid level ........................................................................................	50
(Inspections I, II and III) ......................................................................................................................	50
Checking operation of brake system and freedom from leaks, repairing/repla-
cing if necessary ............................................................................................................................	50
(Inspection III) ....................................................................................................................................	50
Changing brake fluid and bleeding brake system ...................................................	51
Change the brake fluid once a year at the latest ................................................................................	51
(Inspection IV) ....................................................................................................................................	51
Front brake .......................................................................................................................................	51
Forcing back the brake pistons .........................................................................................................	51
Opening the brake fluid reservoir .......................................................................................................	51
Bleeding the front brake pressure modulator ....................................................................................	52
Bleeding the left brake calliper ..........................................................................................................	52
Bleeding the front right brake calliper ................................................................................................	53
Rear brake ........................................................................................................................................	54
Bleeding the rear brake pressure modulator .....................................................................................	54
Forcing back the brake pistons .........................................................................................................	54
Bleeding the brake calliper ................................................................................................................	55
Checking clutch fluid level ....................................................................................................	55
(Inspections I, II and III) ......................................................................................................................	55
Changing the clutch fluid (every 40,000 km/24,000 miles) ..................................	56
Change the clutch fluid every 2 years at the
latest .................................................................................................................................................	56
(Inspection III) ....................................................................................................................................	56
Replacing fuel filter (every 40,000 km/24,000 miles) ...............................................	58
(Inspection III) ....................................................................................................................................	58
Removing the fuel pump unit ...................................................................................................	58
Removing and installing fuel filter ..........................................................................................	59
Installing the fuel-pump unit .....................................................................................................	59
Checking and topping up, if necessary, coolant level and concentration .60
(Inspections I and III) .........................................................................................................................	60
Changing coolant .......................................................................................................................	61
(Inspection IV) ....................................................................................................................................	61
Draining coolant .............................................................................................................................	61
Filling coolant system ..................................................................................................................	62

00.5

Contents - Maintenance	Page
Battery ..............................................................................................................................................	63
(Inspections III and IV) .......................................................................................................................	63
Check battery acid level and add distilled water if necessary; inspect battery terminals and clean and
grease them if necessary ..................................................................................................................	63
Checking battery acid level ......................................................................................................	63
Adding distilled water ..................................................................................................................	63
Installing the battery .....................................................................................................................	63
Replacing intake air filter element ....................................................................................	64
(Inspection III) ....................................................................................................................................	64
Checking function of side stand contact switch ......................................................	64
(Inspections I, II and III) ......................................................................................................................	64
Greasing the side stand ..........................................................................................................	65
(Inspections II, III and IV) ....................................................................................................................	65
Checking the centre stand, greasing if necessary ..................................................	65
(Inspections II, III and IV) ....................................................................................................................	65

Checking the centre stand

Greasing the centre stand

.......................................................................................................65

........................................................................................................65

Checking the steering damper ...........................................................................................	67
(Inspections II and III) .........................................................................................................................	67
Checking tightness of rear wheel studs ........................................................................	67
(Inspection I) ......................................................................................................................................	67
Checking rear wheel bearing play by tilting wheel ..................................................	67
(Inspection III) ....................................................................................................................................	67
Checking swinging arm bearings, adjusting if necessary ...................................	67
(Inspections I and III) .........................................................................................................................	67
Cleaning the inductive sensor on the rear wheel (every 40,000 km/
24,000 miles) .................................................................................................................................	67
Clean the inductive sensor on the rear wheel every two years at the latest .......................................	67
(Inspection III) ....................................................................................................................................	67
Checking valve clearances, adjusting if necessary ................................................	68
(Inspection III) ....................................................................................................................................	68

Checking valve clearances

Adjusting valve clearances

.......................................................................................................68

.......................................................................................................68

Replacing the chain tensioning rail lining and chain guide rail ........................	70
(every 60,000 km/36,000 miles) ........................................................................................................	70
Replacing spark plugs .............................................................................................................	71
(Inspection III) ....................................................................................................................................	71
Final inspection with road safety and functional check .......................................	71
(Inspections I, II, III and IV) .................................................................................................................	71

00.6

00

Tightening torques

Model		K 1200 LT
Connection		Nm
11 Engine
Cylinder head
Cylinder head bolts
Joint torque		20	Oiled before installation
Wrench angle	90°
Cylinder head cover		9
Heat shield for cylinder-head cover		5
Coolant stub pipe		9
Intake stub pipe		9
Split conrods
Split-conrod bearing		20
Wrench angle	80°
Crankshaft
Rotor flange		50
Main bearing		50
Cover, crankcase		9
Freewheel
Cover plate		10
Engine block
Collared bearing, output shaft		40
Needle bearing, output shaft		20
Lower section of crankcase		10
Oil sump		10
Oil drain plug		30
Oil filter cover		10
Oil filter		11
Oil mesh strainer		10

00.7

		Model		K 1200 LT
		Connection		Nm
		11 Engine
		Camshafts
		Bearing cap		10
		Chain sprockets		56
		Intermediate flange
		Thrust plate, driver to intermediate flange		9 (clean thread + Loctite 243)
		Driver to auxiliary shaft		50
		Intermediate flange to engine block		9
		Timing case
		Chain tensioner to cover of timing case		9
		Screw plug for chain tensioner		9
		Timing case cover		9
		Oil/water pump
		Water-pump impeller to pump shaft		33
		Water-pump temperature sensor		9
		Oil pressure switch		35
		Oil pressure relief valve screw plug		35
		Pump housing to crankcase		10
		Cover, pump housing		10

00.8

Model	K 1200 LT
Connection	Nm
12 Engine electrics
Spark plugs	20
Ignition coil
Ignition coil to mounting plate	8
Mounting plate to intermediate flange	9
Cover, shield housing	5
Ignition signal sensor
Rotor	4
Magnetic gate	6
Cover, ignition sensor	9
Alternator
Mount to intermediate flange	20
Driver housing to alternator shaft	50
Connector, lead B+	10
Connector, lead D+	2
Starter motor
Starter motor to gearbox	6
Pinch bolt, starter-motor housing	6
Positive lead to starter motor	6
Earth (ground) lead to cross-tube	6
13 Fuel preparation and control
Air intake connection to cylinder head	9
Hose clips	Hand-tight
Fuel lines to engine	9
Injection rail to cylinder head	9
Retaining plate for cruise control system to
fairing bracket	8
Throttle-valve actuator to throttle-valve rail	5 (clean thread + Loctite 270)
Throttle-valve potentiometer to throttle-
valve rail	2
Temperature sensor to intake air silencer	15

00.9

		Model	K 1200 LT
		Connection	Nm
		16 Fuel tank and lines
		Union nut, fuel-pump unit	30
		Roll-over valve	3
		Immersion-tube sensor	6
		Fuel tank to frame M 8	21
		Bridge to frame M 8	21
		Bridge to frame M 6	9
		17 Radiator
		Hose clips	Hand-tight
		Fan to radiator	2 (clean thread + Loctite 2701)
		Water pump temperature sensor	9
		Coolant stub pipe to cylinder head	9
		18 Exhaust system
		Oxygen sensor to exhaust system	45
		Exhaust system to cylinder head	22
		Exhaust mountings
		Retaining plate to pivot mount	41
		Stirrup to retaining plate	30 (clean thread + Loctite 243)
		Stirrup to silencer	21

00.10

Model		K 1200 LT
Connection		Nm
21 Clutch
Clutch-lever fitting to handlebar		5
Grub screw in filler adapter		10
Filler adapter to breather line		18 (clean thread + Loctite 243)
Clutch housing to output shaft
initial torque		140
release
second torque		50
wrench angle	60°
Cover to clutch housing		18
Lines to clutch slave cylinder		7
Clutch slave cylinder to gearbox		9
Pressure line to clutch fitting		18
Connector, pressure line		10
23 Transmission
Oil drain plug		55
Oil filler plug		30
Speed sensor for reverser to gearbox
housing		6
Housing cover to housing		9
Gearshift linkage
Selector lever to selector shaft		9
Relay lever to transverse tube		9
Ball head to gearshift pedal		8 (clean thread + Loctite 2701)
Gearbox mounts
Gearbox to intermediate flange		24
Clamp, rubber mount		9
Gearbox to frame		70
Reverser
Link from actuator for reverser to
intermediate flange		24 (clean thread + Loctite 243)
Actuator, reverser to link		24 (clean thread + Loctite 243)
Reverse gear switch to actuating shaft		9
Switch unit, reverser to gearbox		9
Actuator lever, reverser		6 (clean thread + Loctite 243)
Cover, reverser to gearbox housing		10
Cover plate, reverser		10 (clean thread + Loctite 243)
Threaded pin M 6 in cover, reverser		5 (clean thread + Loctite 243)

00.11

		Model		K 1200 LT
		Connection		Nm
		31 Front forks
		Fork bridge to frame
		(nut micro-encapsulated)		130 (clean thread + new nut or Loctite 2701)
		Fork stanchion to fork bridge		45
		Steering damper to slider tube bridge
		(screw micro-encapsulated)		21 (clean thread + new screw or Loctite 243)
		Steering damper to leading link		21 (clean thread + new screw or Loctite 243)
		Leading link to fork slider bridge
		(nut micro-encapsulated)		130 (clean thread + Loctite 2701)
		Ball joint to fork slider bridge		230
		Leading link to fork slider bridge		130 (clean thread + Loctite 2701)
		Leading link to frame		107 (clean thread + Loctite 243)
		Clamp, leading link M 8		21
		Spring strut to leading link		43
		Suspension strut to frame		43
		Slider tube bridge to slider tube		21 (clean thread + new screw or Loctite 243)
		Brake distributor to holder, sliding tube right		9
		Oil drain plug in slider tube		12
		Vent screw, stanchion		3
		32 Steering
		Brake-lever fitting to handlebar		5
		Clutch-lever fitting to handlebar		5
		Handlebar to fork bridge		21
		Bearing screw, brake and clutch levers		5 (clean thread + Loctite 2701)

00.12

Model	K 1200 LT
Connection	Nm
33 Rear wheel drive
Oil drain plug	23
Oil filler plug	23
Speed sensor mount	5
Threaded ring	118 (clean thread + Hylomar SQ 32)
Nut, bevel drive pinion	200 (clean thread + Loctite 270)
Housing cover to housing	35
Rear wheel drive to swinging arm
Reaction link to rear wheel drive	43
Reaction link to frame	43
Free bearing stud	7
Fixed bearing stud	160
Locknut	160
Swinging arm to frame
Fixed bearing stud	160
Lock ring	160
Threaded ring, right	200
Threaded ring, left	10
Suspension strut
Handwheel to rear frame	21
Suspension strut to swinging arm	50
Suspension strut to frame	43

00.13

		Model		K 1200 LT
		Connection		Nm
		34 Brakes
		Front brake
		Brake calliper to fork tube		40
		Brake disc to front wheel		21 (clean thread + Loctite 243)
		ABS sensor		4
		Grubscrew in filler adapter		10
		Filler adapter in brake calliper		18 (clean thread + new filler adapter or
				Loctite 243)
		Vent screw in brake calliper		10
		Brake-lever fitting to handlebar		5
		Holder for brake line to sliding tube		4 (clean thread + Loctite 243)
		Brake lines to frame/slider tube M 6		9
		Banjo bolts for brake line		18
		Rear brake
		Brake calliper to rear-wheel drive		40
		Brake disc to rear wheel drive		21 (clean thread + new screws)
		ABS sensor ring to brake-disc carrier		4 (clean thread + Loctite 243)
		ABS sensor		4
		Vent screw in brake calliper		10
		Footbrake lever to footrest plate		41 (clean thread + Loctite 243)
		Holder, stop-lamp switch to footrest plate		5 (clean thread + Loctite 243)
		Locknut for stop screw, foot brake lever		7
		Locknut on piston rod		9
		Brake line to brake cylinder		18
		Brake cylinder to footrest plate		9 (clean thread + Loctite 243)
		Banjo bolts for brake line		18
		Brake line to frame M 5		4
		Retaining plate for brake line to battery
		carrier		4
		ABS pressure modulator
		Bleed screw in ABS pressure modulator		10
		Brake line to ABS pressure modulator		18
		ABS II control unit to battery holder M 5		4
		ABS II control unit to battery holder M 6		9
		Battery holder to frame M 6		9
		Battery holder to frame M 8		21

00.14

Model		K 1200 LT
Connection		Nm
36 Wheels and tyres
Rear wheel mount
Initial tightening		50
Final tightening		105
Quick-release axle, front wheel
Initial tightening		19
Final tightening		30
Pinch bolt, quick-release axle		21
46 Frame
Frame
Engine cross members to main frame		74
Engine cross members to engine		41
Transverse tube to main frame		41
Torsion stop, swinging-arm bushings		Fitted flush with bushing (clean thread +
		Loctite 243)
Skirt bracket M 8		21
Crash bar to skirt bracket		9
Lifter handle to rear frame M 6		9
Rear frame to main frame, top		41
Rear frame to main frame, bottom		41 (clean thread + Loctite 243)
Radiator holder to frame/engine cross
member M 6		10
Radiator holder to fairing bracket/skirt
bracket M 8		21
Fairing bracket
Fairing bracket to main frame M 8		21
Windscreen adjuster to fairing bracket at
side		9
Windscreen adjuster to fairing bracket at
centre		3
Fasteners for retaining plates M 5		4
Fasteners for retaining plates M 6		11
Fasteners for retaining plates M 8		21
Threaded fasteners, mirror plate M 6		9

00.15

		Model		K 1200 LT
		Connection		Nm
		46 Frame
		Footrests
		Footrest system front to frame		21
		Footrest system rear to frame		21
		Footrest rubber to footrest		4
		Shift lever to footrest plate		41 (clean thread + Loctite 243)
		Footbrake lever to footrest plate		41 (clean thread + Loctite 243)
		Stop, footbrake lever		7
		Stop screw, return spring for footbrake lever		5
		Rear section, side cases and top case
		Rear carrier to rear frame		9
		Cover, rear carrier to rear frame		9
		Cover, rear carrier to case		1
		Side case to rear frame		9
		Strap to top of case		2 (clean thread + Loctite 243)
		Case trimmer to rear frame		5
		Case trimmer to case		2
		Top case to rear frame		9
		Armrest to top case		1
		Stands
		Pivot mount to gearbox		41
		Main stand to pivot mount		41 (clean thread + Loctite 243)
		Side stand to pivot mount		41 (clean thread + Loctite 243)
		Fairing
		Fairing screws		2
		Windscreen to windscreen adjuster		2 (clean thread + Loctite 243)
		Cover of fork bridge.		2
		Front mudguard, front, to fork slider bridge
		M 6		4
		Front mudguard, front section, to sliding
		tube M 6		6
		Front mudguard, rear section, to fork slider
		bridge M 6		3 (clean thread + Loctite 243)
		Miscellaneous
		Intake air pipe to fairing bracket		10
		Intake air pipe to radiator holder		10

00.16

Model		K 1200 LT
Connection		Nm
51 Equipment
Non-removable screw for ignition/steering
lock		21
Lock, tank cover to bridge		5
Locking mechanism, front seat to rear frame		5
52 Seat
Bridge, seat to frame M 6		9
Bridge, seat to frame M 8		21
Front hinge, seat to bridge		9
Seat, front, to carrier plate		5
Gas-filled strut to carrier plate for seat, front		21
Seat, rear, to rear frame		9
Backrest, rear, to top case		5
61 General electrical equipment
Retaining plate for fanfare horn to fairing
bracket		21
Ignition lock to fork bridge		21
Wiring harness to main frame		6
Electronics box to main frame		9
Holder for plug and socket connections
behind battery panel, left		9
Attachment, side-stand switch		7 (clean thread + Loctite 243)
Holder, stop-lamp switch to footrest plate		5 (clean thread + Loctite 243)
Locknut for stop screw, foot brake lever		7
Temperature sensor, cylinder head		30
Attachments, battery holder		4
Speed sensor, rear wheel		4
Socket to engine spoiler		4
Socket to top case		4

00.17

		Model	K 1200 LT
		Connection	Nm
		62 Instruments
		Instrument cluster to fairing bracket	6
		63 Lights
		Headlight to upper section of fairing	2
		Rear light cluster to case trimmer	5
		65 Radio and optional extras
		Clamping nut, stub aerial	3
		Aerial holder to frame	9
		Retaining plate for cruise control system to
		fairing bracket	8
		Holder for temperature sensor to upper
		section of fairing	2

00.18

Table of operating fluids

Item	Use	Order number	Quantity
Lubricant
Staburags NBU 30 PTM	High-performance lubricating paste	07 55 9 056 992	75 g tube
Optimoly MP 3	High-performance lubricating paste	07 55 9 062 476	100 g tube
Optimoly TA	High-temperature assembly paste	18 21 9 062 599	100 g tube
Silicone grease 300, heavy	Damping grease	07 58 9 058 193	10 g tube
Retinax EP2	Wheel, steering head and taper roller	83 22 9 407 845	100 g tube
	bearing grease
Contact spray	Contact spray	81 22 9 400 208	300 ml spray
Chain spray	Drive chain	72 60 2 316 676	50 ml spray
		72 60 2 316 667	300 ml spray
Sealants
3-Bond 1110 B	Surface sealant	07 58 9 056 998	5 g tube
3-Bond 1209	Surface sealant	07 58 9 062 376	30 g tube
omni VISC 1002	Surface sealant (max. 200 °C/392 °F)	07 58 1 465 170	90 g tube
Loctite 574	Surface sealant	81 22 9 407 301	50 ml tube
Curil K 2	Heat-conductive sealant	81 22 9 400 243	250 g can
Hylomar SQ 32 M	Permanently elastic sealant	81 22 9 400 339	100 g tube
Adhesives and retainers
Loctite 648	Surface sealant (narrow gap)	07 58 9 067 732	5 g bottle
Loctite 638	Surface sealant (wide gap)	07 58 9 056 030	10 ml bottle
Loctite 243	Thread retainer, medium-strength	07 58 9 056 031	10 ml bottle
Loctite 270	Thread retainer, strong	81 22 9 400 086	10 ml bottle
Loctite 2701	Thread retainer, strong	33 17 2 331 095	10 ml bottle
Loctite 454	Cyanacrylate adhesive (gel)	07 58 9 062 157	20 g tube
Cleaners
Brake cleaner	Brake cleaner	83 11 9 407 848	600 ml spray
Metal Polish	Polish for parts	82 14 9 400 890	100 g tube
Testing agents
Penetrant MR 68	Crack testing agent for aluminium	83 19 9 407 855	500 ml spray
	housings
Developer MR 70	Crack testing agent for aluminium	81 22 9 407 495	500 ml spray
	housings
Installation aid
BMW chilling spray	Chilling components before assembly	83 19 9 407 762	300 ml spray

00.19

00.20

Overview: K1200LT packing materials

00.21

Checking the shipping crate for damage

•When the motorcycle arrives, check the crate immediately for damage and, if necessary, examine the contents for consequential damage.

Damage discovered in Germany

•Note the damage on the delivery slip.

•Read the information sheet on damage in transit.

•Notify the supplier without delay (e.g. freight company or DB) and also

Bavaria Wirtschaftsagentur GmbH Abteilung ZW - 12

80788 München Tel. [phone] Fax. [phone]

Damage discovered in importer markets

•Note the damage on the delivery slip.

•Comply with specific national market procedures. If in doubt, please refer your queries to: Bavaria Wirtschaftsagentur GmbH

Abteilung ZW - 12

D - 80788 München

Tel. [phone] Fax. [phone]

•Notify the supplier (e.g. freight company) without delay.

00.22