Elements of transmission motorcycle BMW K1200LT (1998-2009)

Technical Data of clutch
Technical Data K1200 LT Clutch Type Single dry plate clutch (asbestos-free) Operation Hydraulic Clutch fluid DOT 4 brake fluid Clutch plate dia., mm (in) 180 (7.02) Wear limit: Minimum clutch plate thickness, mm (in) 4.6 (0.18) (measured with tips...

Removing and installing clutch
Preparatory work Remove fairing and engine spoiler. Remove the battery. Slacken exhaust system. Remove the inductive sensor on the rear wheel. Remove the rear wheel brake caliper, fasten to the rear frame with the inductive sensor using a cable tie....

Changing the clutch fluid/bleeding the clutch system
Note: This description applies for the brake filling and bleeding unit with extraction of the brake fluid by a partial vacuum at the brake caliper. If other devices are used, comply with their manufacturers' instructions. Place the motorcycle on its...

Removing and installing clutch lines
Place motorcycle on its centre stand. Remove right side section of fairing. Remove left-hand section of engine spoiler. Slacken exhaust system. Remove rear wheel. Remove rear wheel drive unit. Remove the swinging arm. Drain the clutch operating...

Removing and installing clutch slave cylinder
Remove left fairing section, battery cover and engine spoiler. See Group 46 . Remove the right and left front and rear footrest plates. Remove the exhaust system See Group 18 . Remove the inductive sensor on the rear wheel. Remove the rear wheel...

Removing and installing clutch release rod
Remove left fairing section, battery cover and engine spoiler. See Group 46 . Remove the right and left front and rear footrest plates. Remove the exhaust system See Group 18 . Remove the inductive sensor on the rear wheel. Remove the rear wheel...

Technical Data of gearbox
Technical Data K1200 LT Type of gearbox 5-speed gearbox (4 + overdrive) with integral reverser, claw-action shift and reaction damper. Reverser actuation with lock-out mechanism for forward gears and electric safety elements, plus Hall-effect...

Gearbox — sectional drawing
Gearbox - sectional drawing

Replacing the shaft sealing rings in the gearbox housing and gearbox cover
Note: All shaft sealing rings can be replaced with the gearbox installed, apart from the input-side shaft sealing ring on the input shaft. Replace all shaft sealing rings if the gearbox is fully disassembled. Lightly oil the sealing lips before...

Removing and installing actuating unit for reverser
Removing and installing actuating control for reverser Remove screw (1). Remove actuating control (2) for reverser. Clean threads of screw (1), coat with Loctite 243 and install. Removing and installing actuating unit for reverser Remove skirt....

Removing gearbox
Coution: Disconnect the negative cable from the battery first, followed by the positive cable. Disconnect the battery. Remove the left and right fairing side sections. Remove actuating control for reverser. Remove engine spoiler. Remove left and...

Disassembling gearbox — preparatory work
Remove screw (1) securing starter motor (2) and remove starter motor from gearbox housing. Remove oil filler/level check screw (5). Remove oil drain plug (6) and drain the oil from the gearbox into a suitable tray. Remove breather (3). Remove speed...

Disassembling reverser gear train
Remove eight screws (1). Note: Note the original positions of each of the screws securing the cover of the reverser. Caution: Do not damage the 2 sleeves (cover (2) and gearbox housing). Use M6 adapter, BMW No. 008585, and puller, BMW No. 008580, to...

Removing gearbox housing
Note: Do not drive back centring pins (2, 3). Remove the nine screws (1) securing the cover to the housing. Insert gearbox into mount, BMW No. 23 4 700. Secure press-off tool, BMW No. 23 4 780, to mount of clutch slave cylinder. Avoid damage to the...

Disassembling/assembling selector shaft
Remove torsion spring (13) with locking lever (12) from selector shaft (11). Remove torsion spring (10). Assembly is the reverse of the disassembly procedure.

Removing gearbox shafts
Heat bearing points in gearbox cover to 80°C...100°C (176°F...212°F). Remove input shaft (2), output shaft (3) and intermediate shaft (1) from the cover together.

Replacing grooved ball bearing on intermediate shaft
Caution: Apart from the grooved ball bearings, the intermediate shaft must always be replaced as a complete unit. If the grooved ball bearings are replaced, the fully assembled length must be re-adjusted. Pull off the grooved ball bearings with a...

Disassembling/assembling input shaft
Disassembling input shaft Clamp the input shaft into a vise with soft jaws. Use universal puller, BMW No. 00 7 500, and pressure head (arrow) to pull off grooved ball bearing (9) with spacing washer (8). Note the thickness of the spacing washer....

Disassembling/assembling output shaft
Disassembling output shaft Caution: To avoid damaging the needle roller bearing on the splines, spread the rollers carefully at the end face when removing. Use universal puller, BMW No. 007500, to remove grooved ball bearing (19) together with shift...

Checking endplay
Secure dial gauge, BMW No. 002510, to dial gauge stand. Position dial-gauge stylus on edge of the gearwheel and check endplay. Caution: Excessive endplay is due to incorrect assembly or worn needle roller bearings, backup washers or spacing washers,...

Checking/adjusting fully assembled length of gearbox shafts
Checking/adjusting fully assembled length of intermediate shaft Caution: Check and adjust the fully assembled length as described below and install a spacing washer of the correct thickness. Before measuring, always make sure that the grooved ball...

Assembling gearbox
Installing gearbox shafts Installing input, output and intermediate shafts Caution: Before installing, the gearbox shafts, housing and cover must be thoroughly cleaned and examined for damage. Replace all shaft sealing rings. Check that the gearbox...

Installing gearbox housing
Install pin (arrow) in cover. Caution: Clean and de-grease the sealing faces. The sealing compound sets within 30 minutes; within this time, place the housing in position and tighten the securing screws. Using the metering device, apply Loctite 574...

Installing reverser
Select neutral. Note: Always use a new circlip (2). Introduce actuating shaft into gearbox housing and slip pawl (3) with long lug toward collar and driver (4) with flat toward 5th stage spur gear onto actuating shaft. The pawl must be able to...

Completing assembly of gearbox
Caution: Make sure that breather (1) is correctly seated in groove in bore. Press breather (1) home in bore. Caution: Clean metal particles off the magnet in drain plug (5). Install oil drain plug (5). Insert oil inspection plug (4) with a new...

Installing gearbox
Note: Always install new engine-side and gearbox-side sealing rings for starter motor. Use one hand to press the starter motor profiled sealing ring on the gearbox side into its groove. Install sealing rings. Introduce starter motor (5) into bore in...

Removing and installing gearshift lever and linkage
Slacken screws securing front footrest plate. Remove retainer pin (2). Disengage gearshift linkage at ball joint (1). Remove front footrest plate. Remove bearing screw (8). Remove retaining pin (5). Disengage gearshift linkage at ball joint (6)....

Removing and installing gearshift lever
Remove screw (10). Remove gearshift lever with bearing bushing (9). Installation is the reverse of the removal procedure: pay particular attention to the following. Lubricate bearing bushing (9) with Staburags NBU 30 PTM or equivalent. Clean threads...

Aligning rubber mounts
Aligning left-hand rubber mount Caution: The alignment of the left-hand rubber mounts relative to the frame is preset at the factory. Do not slacken the paint-marked Torx screws (1) unless the rubber mount has to be replaced. Prepare a template as...