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Discussion Starter #1
Hello All,

I am currently servicing my Dec 02 Lt. I am intending to replace all fluids engine, gearbox, final drive, clutch and brake and coolent. I will also replace fuel and air filters and plugs of course. I also intend to put new tyres and brake pads on it.

As I am doing the work myself, I wonder what else the 'experts' among you consider critical to do. I have never set tappets, but I could ask a friend to help me do this, is it a 'must do'. the bike has 75,000 miles on it.

What other must dos are there for a major service. I am told that I should tourqe the final drive, is that correct?

Thanks in advance

Mark
 

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If you don't know the last time the valves were checked, I'd say it's high time. I don't know what you mean by "tourqe the final drive". Finally, I'd ask you if you understand what's involved in changing the brake fluid on this braking system?

Have fun...
 

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Discussion Starter #3
Hello Joe,

Ohh, you sound like the brake fluid change is not trivial? I guess I have some research to do on it. I have the factory manual, but as I have learnt on this bike, nothing is simple on it. The work I am currently doing just to reach the air filter and fuel filter.

Yes, I suppose there is no point in ignoring the valves, I better get my head prepared for it.

I will look up the brake fluid change and let you know what I decide to do, is it a dealer only task?

Thanks Joe

Mark
 

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Discussion Starter #4
Sorry Joe,

I forgot to reply to the Torque the final drive question. Actually I am not too sure also, I have to read up on it but the previous owner mentioned that there is a nut on the drive shaft that must be torqued each year or each major service, he seemed to think that it was important, if / when I find out, I will let you know,

thanks again

Mark
 

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markbreen said:
Hello All,

I am currently servicing my Dec 02 Lt. I am intending to replace all fluids engine, gearbox, final drive, clutch and brake and coolent. I will also replace fuel and air filters and plugs of course. I also intend to put new tyres and brake pads on it.

As I am doing the work myself, I wonder what else the 'experts' among you consider critical to do. I have never set tappets, but I could ask a friend to help me do this, is it a 'must do'. the bike has 75,000 miles on it.

What other must dos are there for a major service. I am told that I should tourqe the final drive, is that correct?

Thanks in advance

Mark
mark ... suggest you also replace the fuel filter.
 

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Discussion Starter #6
Hello Gearad,

I am intending to.

Can I ask, what to you guys to to avoid spilling petrol all over the place when you remove the petrol tank. Siphon most out but then what?

Is there a special tool or bung that you can get to block the hoses when you disconnect them?

Thanks

Mark
 

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I'd say open your factory manual to the maintenance checklist and do everything on the list. That's what the lists are for. I've never heard of torquing the drive shaft, but I would recommend replacing the clutch slave cylinder. Check this thread for more info.

As for the fuel lines, you should have quick disconnect fittings on your '02. If not, then just use a couple of pennies or washers and some vice grips to flatten the hoses. And yes, the less fuel in the tank, the easier it will be to remove.

Where are you located? Many regions set up local tech sessions. Much of the LT maintenance work is pretty trivial once you've seen it done.
 

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Ohh, you sound like the brake fluid change is not trivial? I guess I have some research to do on it. I have the factory manual, but as I have learnt on this bike, nothing is simple on it. The work I am currently doing just to reach the air filter and fuel filter.

Mark,
trivial it is not. Mark Neblett (I think) has a write-up on how to do it in the hall of wisdom. Your factory manual does not cover the 2002 and newer brake system unless you have the proper supplement. Clutch will need bleeding, too.
I second the fuel filter. 2002's have quick disconnects for the fuel tank if yours does not have them someone removed them. They are expensive (~$35 for both) but worth it to put in.
 

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Mark.
Not having a pop at you but if you are not confident I would suggest you leave the service to some one who is and knows how to stop fuel spilling from tank.
The K1200 is a very technical machine and if you misread or misunderstand something out of the manual you are in deep sh*t.

You can read procedures for brain surgery but would you try it?
 

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markbreen said:
Ohh, you sound like the brake fluid change is not trivial? I guess I have some research to do on it. I have the factory manual, but as I have learnt on this bike, nothing is simple on it.
HERE'S A LINK to our Technical section of this forum. A ton of good information in there regarding the brake system. I do 95% of all my own work...but I will continue to let my local dealer do my brake fluid changes. I can change all of the brake and clutch fluid on my Ninja in less than 45 minutes...but the LT doesn't sound like much fun.


markbreen said:
The work I am currently doing just to reach the air filter and fuel filter. Yes, I suppose there is no point in ignoring the valves, I better get my head prepared for it. I will look up the brake fluid change and let you know what I decide to do, is it a dealer only task?
At first, the LT can seem a little overwhelming...but it gets easier with time. Patience is a great tool also. :) Like I stated above, the brake fluid change is NOT a dealer-only task...but that's the choice that I've made. You may want to have your dealer throw the LT on their computer while you have it in the shop also.

Best of luck...and welcome to the forum! Oh, and have fun!
 

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markbreen said:
Hello All,

I am currently servicing my Dec 02 Lt. I am intending to replace all fluids engine, gearbox, final drive, clutch and brake and coolent. I will also replace fuel and air filters and plugs of course. I also intend to put new tyres and brake pads on it.

As I am doing the work myself, I wonder what else the 'experts' among you consider critical to do. I have never set tappets, but I could ask a friend to help me do this, is it a 'must do'. the bike has 75,000 miles on it.

What other must dos are there for a major service. I am told that I should tourqe the final drive, is that correct?

Thanks in advance

Mark
The drive shaft is maintenance free, only thing to inspect is the front and rear u joints. Unless you disassemble , Then you only have to lube upon assembly. Check your shift linkage ball studs, If any found loose replace. As a precaution to sprag clutch failure run some CD-2 detergent prior to your next motor oil change .
 

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goldy said:
Mark.
You can read procedures for brain surgery but would you try it?

Goldy, not trying to have a pop at you, but working on this bike is not brain surgery. As to everything there is a learning curve - I say go for it - go ahead read or watch a procedure and then try it.
 

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Jerrod
If someone is not sure how to stop fuel flowing do you think it is safe to carry on?

I have been a vehicle tech for over 35years and have seen some terrible results in my works after people have read and had a go.

They save £10.00 on bills and spend £100.00 to put it back in shape.

If you are sure you can do it go for it,if not play safe and leave to someone who can.
 
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