1992–1999 BMW K 1100 LT/RS Factory Repair Manual (P/N 01 71 9 799 131)

This BMW AG factory repair manual covers the 1992–1999 K 1100 LT and K 1100 RS in standard specification or with genuine BMW accessories. The 5/99 edition carries publisher reference UX-VS-2; its maintenance and pre-delivery forms carry Order No. 01 71 9 799 131.

Text search and electrical illustrations: The text is searchable, with embedded bookmarks for chapters and individual procedures. Labels in the relay-test and wiring-location illustrations are readable, although lettering within images is not consistently searchable.

• Engine repair: Engine removal, cylinder-head and crankshaft service, timing-chain work, bucket-tappet valve adjustment, and combined oil/water-pump overhaul.

• Fuel preparation and control: Throttle-body synchronization, CO adjustment, Motronic throttle-position-sensor checks, injector removal, and fuel-pump pressure testing.

• Clutch and transmission: Single dry-plate clutch repair, gear-selector-drum and shaft disassembly, transmission measurements, and shim selection.

• Final drive and chassis: Drive-bevel-gear repair, Paralever swingarm service, telescopic-fork overhaul, steering-bearing adjustment, and wheel alignment checks.

• Brakes and ABS: Caliper and master-cylinder repair, ABS I/II removal and installation, ABS II pressure-modulator bleeding, and sensor-gap adjustment.

• Cooling system: Coolant replacement, thermostat testing, radiator and fan removal, cooling-system pressure testing, and overheating troubleshooting.

• Electrical diagnosis: Ignition-timing adjustment, Hall-generator service, alternator and starter repair, troubleshooting charts, relay tests, and wiring-harness location views.

Written for workshop personnel, this manual supplements the theoretical and practical knowledge acquired through BMW training.

Engine Repair and Inspection Routines

Inspection schedules cover the initial service through annual maintenance, with fluid-replacement criteria for the engine, gearbox, rear drive, and telescopic forks.

Internal repair coverage includes piston and cylinder measurement, crankshaft-bearing inspection, valve-seat work, and output-shaft service. LT piston and connecting-rod changes from 1993 are identified separately.

The valve-adjustment section uses BMW camshaft setting tool 11 3 700 and warns that leaving the fixture engaged during final sprocket tightening can damage the camshafts.

Motronic Adjustment and Fuel Supply

Throttle-position-sensor checks distinguish MA 2.1 and MA 2.2. Synchronization instructions describe the BMW Synchrotester's bar and curve displays, while CO adjustment is covered for versions without a catalytic converter.

Detailed fault-memory readout for Motronic MA 2.1 with oxygen-sensor control is referred to the separate BMW Diagnosis booklet, Order No. 01 70 9 798 970, which is not included.

Cooling-System Testing

Thermostat opening checks, filler-cap testing, and cooling-system leak tests accompany radiator, fan, and hose replacement. Troubleshooting charts address a coolant warning light, a fan that fails to start, and coolant loss.

Clutch, Gearbox, and Paralever Setup

Transmission measuring tables relate shaft and cover measurements to shim thickness, helping distinguish input-shaft preload from intermediate- and output-shaft endplay. The gearbox removal notes flag the clutch control rod's vulnerability to bending if the transmission drops out of alignment.

Final-drive coverage includes crown-wheel removal, tooth-backlash adjustment, bevel-gear contact-pattern illustrations, and housing-cover shimming. Torque references cover the clutch housing, cylinder-head bolt versions, and rear-drive threaded ring.

ABS, Forks, and Frame Checks

ABS coverage concerns unit replacement, hydraulic bleeding, sensors, and ABS II relay/base service; it does not include internal pressure-modulator rebuilding. BMW specifies that ABS-unit work is for an authorized BMW workshop. Sensor-gap specifications distinguish through-1996 and 1997-onward applications.

Chassis sections add fork alignment and runout checks, frame-gauge measurements, wheel balancing, and LT/RS fairing removal. The LT adjustable windshield has its own actuator and linkage procedures.

Electrical Fault Tracing and Harness Locations

Separate alternator versions have their own service instructions. Alternator, starter, and battery troubleshooting charts help narrow a fault to the relevant component or connection before replacement.

Electrical illustrations show starter-relay test connections, central relay locations, ABS harness connections, and frame-harness routing. These are location and test views; complete vehicle wiring schematics are not included. Instrument-cluster work covers the circuit boards, clock, tachometer, and speedometer.

Working on motorcycle fuel, electrical, and heavy mechanical systems carries inherent risks, so always use appropriate safety gear and secure the bike properly before starting any major tear-down.

Valve Clearance, Cooling Capacity, and Ignition Coil Data

The valve-clearance table lists intake clearance at 0.15–0.20 mm with the engine cold, up to 35°C, alongside the bucket-tappet adjustment coverage.

Cooling capacity is listed as 3.0 L plus 0.4 L in the expansion tank.

Electrical test specifications include approximately 13 kΩ secondary resistance for the Bosch double ignition coil.

Printable PDF and Included Pages

One English-language printable PDF contains 364 pages, including eight preliminary pages covering the cover, publication and usage notes, two service forms, and contents, plus 41 numbered blank pages within the chapters. All are already included in the total.