BMW K1200RS, K1200GT, K1200LT Repair Manual 1998-2008

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Item # M501-2  ISBN: 9781599692340




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This repair and service manual covers BMW K1200 motorcycle models, including:

• K1200RS 1998-2005
• K1200GT 2003-2005
• K1200LT 1999-2008

Note: this manual DOES NOT cover transverse mounted four-cylinder models.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Warnings, cautions and notes | Safety | Serial numbers and information labels | Fasteners | Shop supplies | Tools | Measuring tools | Electrical system fundamentals | Service methods | Storage | Specifications

CHAPTER TWO: TROUBLESHOOTING
Starting the engine | Engine will not start | Poor engine performance | Fuel system | Engine | Engine lubrication | Cylinder leakdown test | Clutch | Transmission linkage | Transmission | Electrical testing | Final drive | Front suspension and steering | Brake system

CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP
Cylinder identification | Pre-ride inspection | MoDiTeC diagnosis and integral ABS bleed test | Throttle cable operation and adjustment | Engine oil and filter | Transmission | Final drive | Clutch | Brake system | Cooling system | Battery service | Front suspension inspection | Sidestand | Centerstand (manual) | Rear wheel mounting bolts inspection | Swing arm bearing inspection | Speedometer sensor cleaning (ABS II) | Tune-up | Compression test | Air filter replacement | Fuel filter replacement | Valve clearance | Slide rail, tensioner rail lining and thrust piece replacement | Spark plugs | Tires and wheels | Lights and horn inspection | Non-scheduled inspection and maintenance | Rear shock adjustment | Specifications

CHAPTER FOUR: ENGINE
Engine service | Engine | Engine block | Crankshaft cover | Cylinder head cover | Timing cover, cam chain tensioner and crankshaft oil seal | Timing chain, chain guides and camshaft sprockets | Crankshaft rotor flange and sprocket | Camshafts | Cylinder head | Valves and valve components | Intermediate housing and driver | Auxiliary shaft, starter clutch and starter idler gear | Auxiliary shaft and starter clutch overhaul | Auxiliary shaft front bearing and oil seal replacement | Main oil seal replacement | Pistons and connecting rods | Crankshaft | Oil pan, lower crankcase half and output shaft | Output shaft overhaul | Break-in procedure | Specifications

CHAPTER FIVE: CLUTCH
Clutch | Clutch master cylinder | Clutch slave cylinder | Clutch system draining | Clutch system bleeding | Specifications

CHAPTER SIX: TRANSMISSION and SHIFT MECHANISM
Transmission | Transmission rubber bushings | Transmission seal replacement (assembled transmission) | Transmission disassembly | Transmission housing and front cover inspection, bushing and seal replacement | Shift mechanism | Transmission shaft overhaul | Transmission reassembly | Reverse system (LT models) | Specifications

CHAPTER SEVEN: FUEL and EXHAUST SYSTEMS
Fuel injection system | Fuel tank | Fuel filter replacement | Fuel pump replacement | Fuel tank vent and float (RS and GT models) | Fuel level sensor | Roll-over valve (LT models) | Air box | Air intake guide | Fuel pressure check | Fuel rail, fuel injectors and pressure regulator | Throttle body | Fuel hose replacement | Motronic control unit | Air temperature sensor | Coolant temperature sensor | Oxygen sensor | Exhaust system | Carbon canister | Throttle and cruise control cables | Cruise control unit | Specifications

CHAPTER EIGHT: ELECTRICAL SYSTEM (ENGINE)
Battery | Charging system | Alternator | Starting system | Starter | Starter relay | Ignition coil | Hall-effect sensors | Ignition timing | Specifications

CHAPTER NINE: ELECTRICAL SYSTEM (BODY)
Bulbs | Headlight housing | Headlight adjuster cable replacement (LT models) | Turn signal bulb holder | Instrument panel | Electronic equipment box | Relays | Flasher unit | Fuses | Switches | Electrical components | On-board computer (LT models) | Power socket | Horn | Audio assembly | Wiring diagrams | Specifications

CHAPTER TEN: COOLING and LUBRICATION SYSTEMS
Temperature warning system | Cooling system inspection | Hoses | Coolant reserve tank | Radiators | Cooling fans | Thermostat | Coolant pipe | Water | oil pump | Oil cooler housing and thermostat (RS and GT models) | Oil cooler (RS and GT models) | Specifications

CHAPTER ELEVEN: WHEELS and TIRES
Motorcycle workstands | Front wheel | Front wheel bearings | Rear wheel | Wheels | Tires | Specifications

CHAPTER TWELVE: FRONT SUSPENSION andD STEERING
Handlebars, grips and controls | Upper fork bridge | Lower fork bridge and ball joint | Front fork | Front strut | Steering damper | Suspension A-arm | Specifications

CHAPTER THIRTEEN: REAR SUSPENSION AND FINAL DRIVE
Shock absorber | Final drive unit | Final drive unit overhaul | Ring and pinion gear adjustments | Swing arm and front drive shaft | Specifications

CHAPTER FOURTEEN: BRAKE SYSTEM (ABS II)
Brake service | ABS II | Brake pads | Brake calipers | Brake fluid filler adapter | Front master cylinder | Rear master cylinder | Brake disc and sensor wheel | ABS sensor | ABS control unit | ABS relay | Rear brake pedal | Brake bleeding | Specifications

CHAPTER FIFTEEN: BRAKE SYSTEM (INTEGRAL ABS)
Brake service | Integral ABS | Brake pads | Brake calipers | Front master cylinder | Rear master cylinder | Brake disc and sensor wheel | ABS sensors | ABS control unit | Rear brake pedal | Specifications

CHAPTER SIXTEEN: BODY and FRAME (RS AND GT MODELS)
Saddlebags and holder | Seat | Front fender | Windshield and holder assembly | Hand guard | front turn signal housing (- RS models) | Upper fairing | Instrument panel trim (-on RS and GT models) | Fairing side panels | Engine spoiler | Side covers | Grab handle and luggage rack | Lock carrier | Rear section | Rear fender assembly | Left front footpeg and holder | Left rear footpeg and holder | Right front footpeg and holder | Right rear footpeg and holder | Sidestand | Centerstand | Cross-tube | Raising the frame | Specifications

CHAPTER SEVENTEEN: BODY and FRAME (LT MODELS)
Windshield | Front fender | Mirrors | Wind deflector | Front turn signal indicator | Bottom fuel tank cover | Bumper strip | Fairing side panels | Radio compartment cover | Fuel tank cover | Engine spoiler assembly | Handlebar covers | Upper fork bridge cover | Outer instrument cover | Upper fairing | Inner instrument cover | Footrest assemblies | Crash bar assembly | Sidestand | Engine guard and manual centerstand | Engine guard and electro-hydraulic centerstand (EHCS) | Seats | Battery covers | License plate holder | Trunk | Rear trunk trim | Saddlebags | Cross-tube | Raising the frame | Specifications

COLOR WIRING DIAGRAMS

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

BMW K1200RS, K1200GT, K1200LT Repair Manual 1998-2008