K1200LT clutch parts list - BMW Luxury Touring Community
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post #1 of 15 Old Mar 2nd, 2016, 3:48 pm Thread Starter
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K1200LT clutch parts list

Since there have been a large number of clutches replaced this winter with lots of people asking what parts do I need to replace when I do this, I thought I would pull together a comprehensive list and post if hopefully for easy searching. Prices listed are OEM from MAX BMW as of 3/2/16.

Some have gone to other sources for seals as they are available in the sizes listed and Beemer Boneyard has clutch friction disks in several varieties from better than OEM to an oil resistant one. There is plenty of tech savvy people here for those wishing to turn their own wrenches, all you need do is ask.


Clutch Parts
21 21 7 688 214 DIAPHRAGM SPRING $84.88
21 21 2 332 974 PRESSURE PLATE $117.35
21 21 7 670 455 CLUTCH PLATE - D=180MM $204.79
21 21 2 333 449 HOUSING COVER $224.02
21 21 1 454 417 SCREW ( clutch cover 6 needed ) $2.35
21 21 1 242 377 WASHER - A7,4 ( clutch cover 6 needed ) $0.64
11 21 1 460 673 HEX NUT - M20X1,5 $11.14
11 21 1 460 696 COMPRESSION RING $4.76
11 21 1 464 939 STOP DISK - GROSS $19.90
11 21 1 460 467 O-RING - 19X4 (OEM not Viton) $1.88

Seals
11 11 7 666 186 SHAFT SEAL - 50X80X10 ( rear main block seal behind clutch basket) $34.70
23 12 7 705 086 SHAFT SEAL - 20X32X8 ( Trans input shaft seal ) $19.35
23 12 2 330 135 SHAFT SEAL - 25X40X6 ( Trans output shaft seal set depth critical) $19.35
23 12 7 705 085 SHAFT SEAL, DRIVE SHAFT - 17X28X7 ( under slave cyl seal) $17.58

Slave cylinder
21 52 2 333 433 OUTPUT CYLINDER CLUTCH - D=20 $176.82

Gordon
Sugar Hill, GA
2001 K1200LTI Champagne (current ride) Lazy Susan
1998 R1100RT Never should have sold it
1974 Yamaha TX 750 Twin. Omni Phase Balanced


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post #2 of 15 Old Mar 2nd, 2016, 9:40 pm
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Re: K1200LT clutch parts list

Thanks for posting the parts list. I will save it to a place I can't lose it for when its my turn to attempt the clutch replacement.

Were there any "special" tools that were required to complete the job? If there were, where did you purchase it. Additionally, did you have a favorite thread you referred too to research the disassembly/reassembly process or did you exclusively reference the Clymer's manual?

Rob, 2000LT
Navarre, FL
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post #3 of 15 Old Mar 2nd, 2016, 10:17 pm Thread Starter
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Re: K1200LT clutch parts list

Quote:
Originally Posted by Fun Bobby View Post
Thanks for posting the parts list. I will save it to a place I can't lose it for when its my turn to attempt the clutch replacement.

Were there any "special" tools that were required to complete the job? If there were, where did you purchase it. Additionally, did you have a favorite thread you referred too to research the disassembly/reassembly process or did you exclusively reference the Clymer's manual?

Rob, 2000LT
Navarre, FL
I used the Clymer manual, the experience of Panzer who did it by himself and a set of tools made by Panzer and a couple made by myself. I made the cut out 30mm socket and also made a seal driver from washers for the trans output shaft seal unarguably the most critical for being set properly or it will leak buckets. The special tools make the seal setting very quick. Just hammer it in and move on. Removing the old seals takes some care using the drill and screw method so not to let the drill wander into the case walls and gouge the soft aluminum at the edge of the seals. Go slow and be careful. The rear main aluminum seal is a bugger to get out but it will come, just don't damage the bearing inside.

There are a couple of really good tips like leave the reverse switch attached to the transmission and don't try and remove the wire from the starter, remove it from the junction block just in front of the rear fender and snake the wire through.

If you have a second set of hands to lower and raise the transmission, that is very helpful.

As for threads, there are plenty that I read and just familiarized myself with what I was undertaking for a $1.83 cent O-ring. I had help from the major players on this forum and also in person but many or most do it all by themselves successfully. It just takes a little longer.
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Gordon
Sugar Hill, GA
2001 K1200LTI Champagne (current ride) Lazy Susan
1998 R1100RT Never should have sold it
1974 Yamaha TX 750 Twin. Omni Phase Balanced


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post #4 of 15 Old Mar 9th, 2016, 6:30 am
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Re: K1200LT clutch parts list

Since I don't know what the heck I'm doing, I have to ask - are all those parts needed, or I won't know until I get it apart? Reason I ask is some of those things like

21 21 2 333 449 HOUSING COVER $224.02

seem like maybe they don't wear. Or is it best to do the whole list once you're in there?

If I have this shop do it, I'm going to have to anticipate everything since I don't think they're going to dismantle it and then tell me what parts to order.

Regards,
Michael

2009 R1200RT
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post #5 of 15 Old Mar 9th, 2016, 7:06 am
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Re: K1200LT clutch parts list

Quote:
Originally Posted by mmnich View Post
Since I don't know what the heck I'm doing, I have to ask - are all those parts needed, or I won't know until I get it apart? Reason I ask is some of those things like

21 21 2 333 449 HOUSING COVER $224.02

seem like maybe they don't wear. Or is it best to do the whole list once you're in there?

If I have this shop do it, I'm going to have to anticipate everything since I don't think they're going to dismantle it and then tell me what parts to order.
These 3 items are optional as they normally do not wear a lot - it really depends on total mileage and usage - you will know after inspection:
21 21 7 688 214 DIAPHRAGM SPRING $84.88
21 21 2 332 974 PRESSURE PLATE $117.35
21 21 2 333 449 HOUSING COVER $224.02

If you or the original owner DID NOT overheated the clutch (or friction-disk down to rivets), then the COVER and PRESSURE-PLATE could be re-used ASSUMING they are nor warped and have good surface.

As far as the DIAPHRAGM SPRING is concerned it is a bit of a crapshoot. In most cases it can be re-used, but with age / mileage it does loose a bit of tension. Very difficult to evaluate unless you have special tooling to compare new and old (they are no specs published for tension). When you put OLD and NEW spring side-by-side on a flat surface, you can see a bit of difference in height or curvature.
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K1200RS (2002 IceBlue/Red - 96,000 miles)
-------------------------------------------------
Think twice before you hit [SUBMIT REPLY] - famous quote by another member:
"The value of this board is not founded on dismissing the ideas of others, but by posting to share our experiences and what we've learned from them."
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post #6 of 15 Old Mar 9th, 2016, 7:20 am Thread Starter
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Re: K1200LT clutch parts list

Quote:
Originally Posted by mmnich View Post
Since I don't know what the heck I'm doing, I have to ask - are all those parts needed, or I won't know until I get it apart? Reason I ask is some of those things like

21 21 2 333 449 HOUSING COVER $224.02

seem like maybe they don't wear. Or is it best to do the whole list once you're in there?

If I have this shop do it, I'm going to have to anticipate everything since I don't think they're going to dismantle it and then tell me what parts to order.
How much you do depends on why you are replacing the clutch. If there are no leaks and it is simply worn out, then the absolute minimum would be this

21 21 7 670 455 CLUTCH PLATE - D=180MM $204.79 (Friction disk)
21 21 1 454 417 SCREW ( clutch cover 6 needed ) $2.35
21 21 1 242 377 WASHER - A7,4 ( clutch cover 6 needed ) $0.64
11 21 1 460 673 HEX NUT - M20X1,5 $11.14
11 21 1 460 696 COMPRESSION RING $4.76
11 21 1 464 939 STOP DISK - GROSS $19.90
11 21 1 460 467 O-RING - 19X4 (OEM not Viton) $1.88

If you have contamination from oil or any signs of leaking then you would need some component of these depending on what is leaking.


Seals
11 11 7 666 186 SHAFT SEAL - 50X80X10 ( rear main block seal behind clutch basket) $34.70
23 12 7 705 086 SHAFT SEAL - 20X32X8 ( Trans input shaft seal ) $19.35
23 12 2 330 135 SHAFT SEAL - 25X40X6 ( Trans output shaft seal set depth critical) $19.35
23 12 7 705 085 SHAFT SEAL, DRIVE SHAFT - 17X28X7 ( under slave cyl seal) $17.58

The hard parts may or may not be reusable. the cover and pressure plate wear in a dish pattern and if severe enough with a new friction disk, may not have enough surface contact to prevent slippage or may cause warpage from uneven heating.

The diaphragm spring is a coin toss as i have heard others say. It will eventually over time lose some of its spring tension and cause slippage from insufficient pressure.

21 21 7 688 214 DIAPHRAGM SPRING $84.88
21 21 2 332 974 PRESSURE PLATE $117.35
21 21 2 333 449 HOUSING COVER $224.02

The slave cylinder is another issue if it leaks and can contaminate your clutch causing it to leak. If it isn't leaking, it doesn't need to be replaced but I would drill the weep hole so you have the chance of knowing there is something wrong hopefully before it contaminates your new clutch.

Slave cylinder
21 52 2 333 433 OUTPUT CYLINDER CLUTCH - D=20 $176.82


Like I said in my first post, it was a comprehensive list of the parts you could expect to need replacing and I will add, depending on your reasons for doing the clutch replacement being a leak or just wear.

If your bike is 15 years old like mine, I did almost everything on that list with the exception of the clutch cover and pressure plate in hopes that I would have a better experience later as I continue to ride her knowing I did not have 15 years old parts and seals waiting to cause me to pull it apart again a year or two later and do it again. That is an individual choice for certain. I hope I don't regret not replacing the hard parts later in a year or two.


I am adding a picture of the type of wear you can expect to find on the hard parts. If severe enough, more than a few thousandths they should be replaced.

Good luck on deciding what you need to do.
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Gordon
Sugar Hill, GA
2001 K1200LTI Champagne (current ride) Lazy Susan
1998 R1100RT Never should have sold it
1974 Yamaha TX 750 Twin. Omni Phase Balanced


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Last edited by bmwcoolk1200; Mar 9th, 2016 at 9:36 am.
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post #7 of 15 Old Mar 9th, 2016, 7:27 am
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Re: K1200LT clutch parts list

Great information, thank you for sharing. With less than 3500 miles on my LT, it will be a while before I do this but it is always good to gather information beforehand.
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post #8 of 15 Old Mar 9th, 2016, 7:31 am Thread Starter
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Re: K1200LT clutch parts list

Quote:
Originally Posted by jd50i View Post
Great information, thank you for sharing. With less than 3500 miles on my LT, it will be a while before I do this but it is always good to gather information beforehand.
Yes, with only 3500 on the clock, wear shouldn't be of much concern unless it was abused. Age of the seals and that pesky O-ring are of more concern depending on your year.

Gordon
Sugar Hill, GA
2001 K1200LTI Champagne (current ride) Lazy Susan
1998 R1100RT Never should have sold it
1974 Yamaha TX 750 Twin. Omni Phase Balanced


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post #9 of 15 Old Mar 9th, 2016, 7:44 am
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Re: K1200LT clutch parts list

It's an 08. I edited my signature but it doesn't show. I'll keep looking at it.

1973 CB 450K6
1975 CB 500T
1985 CB 650SC Nighthawk
1985 VF 1100S Sabre
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post #10 of 15 Old Mar 9th, 2016, 11:12 am
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Re: K1200LT clutch parts list

I was quoted 10 hours to do the clutch. Can I get an idea how many hours on top of that and what additional disassembly is required to do the seals?

Regards,
Michael

2009 R1200RT
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post #11 of 15 Old Mar 9th, 2016, 11:32 am Thread Starter
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Re: K1200LT clutch parts list

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Originally Posted by mmnich View Post
I was quoted 10 hours to do the clutch. Can I get an idea how many hours on top of that and what additional disassembly is required to do the seals?
All the transmission seals are readily available once the transmission is out. It took Me and Panzer probably 30 minutes to change the input, output and slave cavity seals with it on the bench. the output shaft seal is the most critical for placement as there is an oil hole on the shaft directly behind the seal lip. Too far and it leaks. Ask me how I know this

Posting a picture of the output shaft and where the seal rides so you can see just how close it is.

The O-ring is accessible under the big nut and compression ring. To remove the clutch basket, this has to be removed to be replaced and it should without any doubt be replaced even if it is with the stock O-ring and not the after market Viton variety. The rear main is teflon and would be a crap shoot if you left it in with no signs of leaking on how long it would last. I would say pulling the clutch basket and replacing the rear main seal and the O-ring with the thrust washer and reinstalling it would add another hour to an hour and a half with proper cleaning. If you really know what you are doing, that could be shorter. Having the proper seal setting tools makes these go very fast once they are removed.

I have never worked in a shop so these are estimates on my own job in my garage. I would say at least another two shop hours to replace those seals if they are not included in the original estimate.

Your experience may vary.
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Gordon
Sugar Hill, GA
2001 K1200LTI Champagne (current ride) Lazy Susan
1998 R1100RT Never should have sold it
1974 Yamaha TX 750 Twin. Omni Phase Balanced


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post #12 of 15 Old Mar 21st, 2018, 11:29 am
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Re: K1200LT clutch parts list

What about exhaust gaskets
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post #13 of 15 Old Apr 1st, 2018, 4:35 pm
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Re: K1200LT clutch parts list

thanks all

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? when to ASUME, and HOW MUCH should you ASUME, safely ?
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post #14 of 15 Old Apr 1st, 2018, 7:06 pm Thread Starter
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Re: K1200LT clutch parts list

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Originally Posted by gogofaster View Post
What about exhaust gaskets
You are supposed to replace those but I didn't and have had no leaking issues. If I pull the exhaust a second time, I will certainly replace them. Be careful on reading the torque specs out of the Clymer manual as my edition was incorrect listing 44 Ft Lbs when it should be 16 for us Americans.

Price as of this posting at MAX BMW
11 62 7 662 083 GASKET RING - C32X40 4 needed at $3.39ea
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Gordon
Sugar Hill, GA
2001 K1200LTI Champagne (current ride) Lazy Susan
1998 R1100RT Never should have sold it
1974 Yamaha TX 750 Twin. Omni Phase Balanced


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post #15 of 15 Old Apr 1st, 2018, 7:36 pm
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Re: K1200LT clutch parts list

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Originally Posted by bmwcoolk1200 View Post
You are supposed to replace those but I didn't and have had no leaking issues. If I pull the exhaust a second time, I will certainly replace them. Be careful on reading the torque specs out of the Clymer manual as my edition was incorrect listing 44 Ft Lbs when it should be 16 for us Americans.

Price as of this posting at MAX BMW
11 62 7 662 083 GASKET RING - C32X40 4 needed at $3.39ea
If you do replace them I would re-torque them a few times after a few heat cycles.
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