1998–2009 BMW K 1200 LT Service & Repair Manual (P/N UX-VS-2)

This BMW K 1200 LT repair manual covers maintenance, diagnosis and mechanical repair, with procedures for standard motorcycles and genuine BMW accessories. Produced in July 1999, it includes equipment-specific instructions for configurations such as cruise control and heated grips.

• Engine repair: Engine removal, cylinder-head overhaul, crankshaft and piston inspection, bucket-tappet replacement, camshaft timing, and combined oil/water-pump service.

• Fuel and cooling: Motronic diagnosis, fuel-pressure testing, in-tank pump and filter replacement, fuel-level sensor calibration, radiator service, and cooling-system troubleshooting.

• Clutch and gearbox: Dry-clutch replacement, hydraulic bleeding, gearbox disassembly, shaft measurement and shimming, plus electric reverser gear-train and switch-unit service.

• Suspension and final drive: Telelever fork and leading-link work, Paralever bearing service, bevel-drive overhaul, backlash adjustment, and tooth-contact checks.

• Brakes and wheels: Caliper piston service, ABS pressure-modulator bleeding, sensor-gap adjustment, wheel-bearing replacement, balancing, and rim-runout checks.

• Electrical and touring equipment: Starter overhaul, alternator service, wiring-harness views, fairing removal, and procedures for instruments, radio controls, and the on-board computer.

Written for workshop personnel as a supplement to BMW training, this manual is suited to technicians with the experience, diagnostic equipment and special tools needed for its advanced procedures.

Engine Repair and Scheduled Maintenance

Inspection routines I–IV connect the maintenance schedule to the applicable service procedures. Torque tables, operating-fluid references and wear limits support the individual jobs.

The engine chapter covers valve-seat machining, piston and cylinder measurement, crankshaft-bearing clearance checks, and starter-freewheel repair. Engine cutaway and assembly illustrations accompany the work, with BMW special tools identified where required.

Bucket-tappet adjustment includes camshaft removal and alignment with BMW tool 11 3 700. The timing instructions warn that incorrect piston positioning during camshaft work can damage both valves and pistons.

Motronic, Fuel Delivery and Cooling Diagnosis

Motronic MA 2.4 coverage includes fault-memory retrieval, throttle-potentiometer adjustment and actuator function checks through MoDiTeC. Separate throttle-cable procedures distinguish motorcycles with and without cruise control, including cruise-control disengagement and setting problems.

Fuel-system procedures include pressure-regulator and injector replacement, fuel-pump access, and immersion-tube sensor calibration after tank or sensor replacement. The pressure-test section identifies the pump, filter, regulator and lines as checks when supply pressure is low.

The coolant-circuit drawing and troubleshooting charts address overheating, fan failure, coolant loss and slow warm-up. These charts help distinguish circulation problems from fan-control faults before choosing a component to replace.

Clutch, Gearbox and Bevel-Drive Overhaul

Clutch coverage includes the housing, hydraulic slave cylinder, release rod and pressure lines. Gearbox sectional drawings support internal disassembly, bearing replacement, assembled shaft-length measurement and selector-shaft shimming.

The reverser section documents its gear train, double switch, actuator installation and functional checks. Rear-drive cutaway drawings accompany pinion and crown-wheel work, tooth-contact assessment and housing-cover shimming for bearing preload.

Telelever, ABS and Touring Bodywork

Suspension procedures include fork-seal replacement, leading-link measurement and steering-damper inspection. The steering-damper instructions specifically warn that incorrect screw length can damage the damper.

ABS II coverage includes sensor-ring runout checks, sensor-spacing adjustment, relay replacement and pressure-modulator removal. BMW assigns ABS control-unit work to authorized BMW workshops; consult a qualified technician if brake or chassis work exceeds your experience.

Fairing procedures identify mounting points and panel relationships. Windshield-adjuster, side-case and top-case work is also included, alongside seat-removal instructions that account for heating connections and access around the optional CD player.

Electrical Component Views and Accessory Service

Electrical sections cover Hall-effect ignition timing, starter brushes, alternator drive components and the voltage regulator. Radio/cassette-player, speaker, remote-control and cruise-control-unit removal procedures address the touring equipment.

Relay positions in electronics box and Wiring colours provide labeled component and instrument-connection references. Electrical coverage uses harness-routing and connector-location views; it does not include a complete circuit-schematic set.

Examples of Valve and Brake Inspection Data

These are a small selection of the adjustment and inspection specifications in the manual.

For valve-clearance checks with the engine cold, no warmer than 35 °C, the intake range is 0.15–0.20 mm and the exhaust range is 0.25–0.30 mm. The related procedures cover selecting replacement bucket tappets.

The brake tables specify a 6.5 mm minimum rear-disc thickness and a 0.45–0.55 mm gap for both front and rear ABS sensors. Sensor adjustment is documented together with sensor-ring runout checks.

Searchable PDF with Procedure Bookmarks

Text search and illustrated references: Searchable text and embedded bookmarks provide access to chapters and individual procedures. Small labels in the relay, connector and instrument-wiring views remain legible when enlarged.

One printable, English-language PDF contains 452 pages. This total includes eight preliminary pages covering the cover, publication details, introductory material, contents, maintenance schedule and pre-delivery check; the two checklists carry Order No. 01 71 9 799 278. The 48 otherwise blank chapter pages are also included in that total.