Model | K1200 LT |
Connection | Nm |
11 Engine | |
Cylinder head | |
Cylinder head bolts Joint torque Wrench angle 90° | 20. Oiled before installation |
Cylinder head cover | 9 |
Heat shield for cylinder-head cover | 5 |
Coolant stub pipe | 9 |
Intake stub pipe | 9 |
Split conrods | |
Split-conrod bearing Wrench angle 80° | 20 |
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 |
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 |
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 throttlevalve rail | 2 |
Temperature sensor to intake air silencer | 15 |
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 |
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 release second torque wrench angle 60° | 140 50 |
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) |
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) |
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 |
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 |
36 Wheels and tyres | |
Rear wheel mount Initial tightening Final tightening | 50 105 |
Quick-release axle, front wheel Initial tightening Final tightening | 19 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 |
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 |
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 |
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 |