BMW K75 Betriebsanleitung

Repair Manual

K75 – K100 LT

All 2V Models

BMW Motorrad GmbH + Co.

Service Department

dated: 4.1988 scann: 12.2011 Order No: 01 51 9 798 791

by a kind approval of the BMW AG for

www. flyingbrick . de

This manual is based on the org BMW Repair manual

This file is an almost global cooperation to assure that all information for our

old bikes will be available after the org book is sold out.

Involved:

Australia, UK ,Ireland , Canada, Germany

Printing:

Take a modern laser printer (duplex) and print each chapter seperatly.

Org.size is A5, printing in A4 is possible

The file only shows the K-Models up to 1988.

Not shown is: ABS 1 – for that you’ve to take the K1100 file

I´ve only added infos in chapter 31 for K75 Showa frontfork from 8.1991 up

Thx and regards to all who made it possible

6.12.2011

by a kind approval of the BMW AG for

www. flyingbrick . de

Tableofcontents

Section Chapter Page

00 Maintenanceand general instructions

00-01.0

Introduction

00-03.0

Engine . . .

11-01

12 Engine-electrical system .

12-01.0

13 Fuel supplyand mixture contraI

13-01.0

Fuel tankand lines

16-01.0

Radiator

. .

17-01.0

18 Exhaustsystem

18-01.0

Clutch .

21-01.0

23 Gearbox

23-01.0

Frontfork

31-01.0

Steering .

32-01

Rearwheel drive .

33-01.0

Brakes

......

34-01.0

Wheels and tyres

36-01.0

Frame, fairing

46-01.0

Equipment .

51-01.0

Dualseat

52-01.0

General electrical system

61-01

62 Instruments

62-01.0

63 Lights

63-01.0

8.87

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CI)

-c

c: c:

c:+:

CI)

(.)

....

::l

....

:EC:

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00 Maintenanceand general instructions

Introduction . . . . . . . . . . . . . .

Tighteningtorquesto BMW

standards.

Conversion and comparisonstable . .

Fromdelivery

themotorcycleuntil sale

Removing motorcyclefrom crate . . .

Checking motorcycleformissing items

Completingthe motorcycle . . .

Pre-deliverycheck

Battery-removing and installing

Battery-filling with acid . . . . .

Battery-charging

.......

Brakefluid

..........

Tighteningtorques andtyre

pressures-checking

Lights and

dicators-checking

Final functional check .

Final remarks . . . . . . . . . .

BMW

maintenanceand inspection chart

Driveline

..........

Frame

............

Servic

g materials, K

models.

. , .

Servicedata

...........

Engineoil viscosity chart . . . . . .

Determining engineo

consumption

Drivelinemaintenanceand servicing

Engineoil-changing

.......

Gearoil-chang

ing

........

Final drive

oil-

changing . . . . . .

Rearwheel inductivetransmitter-cleaning .

Sparkplug electrode gap-checking . . . .

Determining state

enginefrom spark plug.appearance

Sparkplugs-renewing . . . . .

Clutch cablenipple-greasing

Clutch

play-checking,

adjusting

...

. .

......

Valve

play-checking,

adjusting ....

.......

Aircleaner element-removing and installing . . . . . .

Cableplay (throttle, increased starting speed)-checking .

Framemaintenanceand servicing

Oil

telescopicfork-changing . .

Steering bearing

play-checking,

adjusting

Fuel filter-renewing . . . . . . . . . . .

Brakes-checking

.. ..

.....

Brakefluid-changing . . . . . . . . . . .

Brake padsand

discs-checking

forwear

Batteryacid

level-

checking .

.....

Coolantconcentration-checking . . . . .

Freetravel atfootbrake

-checking,

adjusting

Screwsand nuts-taking up slack .

Finalcheck . . . . . . . . . . . . . . . . .

00-03.0

00-05.0

00-07

00-11.0

00-14.0

00-15.0

00-

00-22.0

00-23.0

-23.0

00-25

00-27

00-28.0

-29.0

00-30.0

-30.0

-31.0

00-32.0

-32.0

00-33.0

00-34.0

00-35.0

00-36.0

-4

0.0

00-42.0

00-43

00-45.0

00-46.0

00-48.0

00-49

00-49.0

00-51

-51.0

-52.0

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Introduction

This Workshop Manual covers K series 3- and 4-cylinder models. Wherethere are differencesbetween 3- and

4-cylinder models,the symbol 1

•••

1 relers to the3-cylinderversion and I

••••

1 to the 4-cylinder

version. IIadeviation appliesto only one

two models, the relevant models designation is stated directly.

This Workshop Manual is intendedto help you carry outall the majorrepairand maintenanceoperations on the

motorcycle correctly.

should be relerred to whenever necessary byworkshop personnei, as an extension

thetheoretical and practical knowledge acquired at our Service Training School. Relerencetothis inlormation

essential as a means

increasing the quality

servicingworkstill lurther.

When the contents

the Workshop Manual have to be added to

amended, this issue will be replaced. The

relevant sections

the contents are marked with the

new

issue date. Old Workshop Manual microliches

should be destroyed.

All illustrations and texts reler to motorcycles to standard specilication

equipped only with Genuine

BMW

Accessories,and

notto

motorcycleswhich have beenotherwise modilied

anyway.

Instructions

lor

use:

• The order

appearance in this Manual is accordingto main group numbers00 ...

,as also used

the Flat

Rate Manual.

• Group 00 includes a

maintenance, inspection and adjustment procedures, togetherwith the technicaldata

required

lorthese

tasks.

• The tasks involved in a motorcycle inspection are listed in a maintenance and inspection chart. The extent

inspection and maintenance work is coded I,

111.

These codes are also given with the subsequent

description

each procedure in orderto permit uninterruptedwork.

• Example

page numbering:

,,---------,3

3 -

OlL.:

====::::::;--

Main assembly

group Page numberwithinassembly group 'Supplementary'

pages

• Use

BMW

SpecialTools is explained

the individualwork descriptions.

• Detaching/removing

dismantling/stripping work is normally described. II the procedures

lor

removal and

reinstalling are identical except

the reverse order, only the procedure

lor

removal

described and an

appropriate note

provided.

Repair instructions are also issued as Service Inlormation when necessary. The details are incorporated into

the next issue

the Workshop Manual. As an aid to repair and servicing work, you are also recommended to

consultthe illustrations in the Parts microliche.

BMW

Motorrad GmbH +Co.

Technical Service Department

Published by:

BMW

Motorrad GmbH +Co.

Triebstraße32

8000 Munich 50

Federal Republic

Germany

All rights re

rved. Notto be reprinted, translated or reproduced wholly orin part without wrilten permission.

Subjecttotechnicalamendments;errors and omissionsexcepted.

Printed

West Germany 00-03.0

by a kind approval of the BMW AG for

www. flyingbrick . de

Tightening torques

BMW

N600

Valid onlyforbolts and screwsto

German

DIN 912, 931, 933, 960, 961 and 6912 standard and nuts with a height

0.8

dto

DIN

934

standard, sOlelyfortotal1l = 0.14

(Boltor

screwphosphatised, nutgalvanized

untreated. Eitheroiled

dry.)

For cadmium-plated bolts

nuts(total

0.08 to 0.09) thetightening torque for the

same

strength limit utilisation

theboltmaterial mustbe

30%

lowerthan statedinthetable.

Not

valid if the thread has any other surface treatment

lubrication,

for different nut heights. In such cases the

valuesmustbe speciallycalculated.

Not valid for screws

bolts

the expansion type, for self-locking threaded connections

when components

made

from differentmaterialsare usedtoformthethreadedjoint.

Thestrength utilisationfactorforballswith standard metricthread is:

~E>d

-o,üg:-o?2]

TighteningtorqueMA (Nm)

Tighteningtorque, max. (Nm) Threadedconnectionclass

111

Msp = MAmax. MA

= 0,

Msp

12%

Strengthclassification ace. to DIN 267 Strength classificationace. to DIN 267

Thread 5.6 6.8 6.9 8.8 10.9 12.9 5.6 6.8 6.9 8.8 10.9 12.9

4.7 7.5 8.4 9.9 14.0 16.5 4.2± 0

6,7± 0,8 7.5±

0.9

8.8±

1.1

12.5± 1.5

.7± 1.8

11.0

.0 20.0 24.0

.0 9.8±

1.2

16.0±

17.8± 2.1

21.4

± 2.6 30.3± 3.6 35.6± 4.3

M10

.0 36.0 40.0 47.0 66.0 79.0 20.5±

2.5

.0± 3.8 35.6±

4.3

41.8±

5.0

58.7± 7.1 70.3± 8.4

x 1 12.0 19.5 22.0 25.0 36.0 44.0

10.7

± 1.3 17.4± 2.1 19.6± 2.4 23

± 2.8

.0± 3.8 39.2± 4.7

M10

x 1 25.0 40.0 45.0 54.0

.0 91.0 22.3± 2.7

.6± 4.3

± 4.8 48.1 ± 5.8 66.8± 8.0 81.0± 9.7

M12

x1.5 41.0 55.5 73.5

.0 123.0

147

.0 36.5± 4.4 49.4±

5.9

65.4±

7.9

77.4±

9.3

109

.5±

130

±15.7

M14x1.5

67.0 107.0 120.0 143.0 200.0 240.0 50.7± 6.! 95.2±

11.4

106.7±

12.8

127.3±

178

.0±

21.4

213.6±

256

M16

.5 101.0 162.0 182.0 216.0 303.0

364

.0 89.9±

144

.2±

.3 162.0±

19.4

192.2±

23.1

269

.7±32.4

324.0

±38.9

M18x1.5

147

.0 234.0 264.0

313

.0 440.0 527.0 130.8±

.7 208.3

±25.

0 235.0

±2

278.6

±33.4

391 .6±

.0 469.0±56

M20x1

.5 204.0 326.0 367.0 435.0 612.0 734.0 181.6

±2

1.8

290.1

±34.

326

6±39.2

387.2±

46.5

544.7

±65.4

653.3

±7

The values stated in the above tables apply

threaded connections in accordance with the above conditions.

The

tighteningtorqueincludingtolerance isonlyindicated

thegeneral arrangement

assembly

drawingif:

a) avaluewhich differsfromtheStandard is neededforfunctional reasons,

b) thestrength classification

thebolt and nutis notevident.

Importantnote:All deviationsfromthistableareindividuallystated in the Specifications.

8.87

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8.87

Conversion and comparisontablefor

statutory measurementunits

unitsymbols Values

Nameofunit old new

Length m m 1m = 1000mm 1

= 1000m

Il-'m

= 0

Area m' m'

lm'

=10·mm' 1mm' =

0.01

cm'

sq.m

1m' = 1

0·cm

' 1

' =

0.001

Volume

I I

= 1dm'

surface ° °

rad

1rad = 1mim = 57° 1° =

,,/

180

rad

Angle spatial (0)' sr 1sr = 1m

°)' =

180)

Mass

kg kg

lkg

1000g

1g = 1000mg

IMg

=1000kg

Density kg/m' kg/m' 1kg/m' =

0.001

' 1kg/dm' = 1kg/I

Imbalance kgm kgm 1kgm = 1000000 gmm

Time sec 1min =

60s

1h = 60mins

Speedof rotation rps l /s 1rpm = l /min l /min = 1/(6

0s)

rpm

l/min

Speed (velocity) m/s m

1m/s = 3.6

Acceleration m/s' m/s'

Force kp N 1N = 1kgm/s' 1

9,81

alm 1atm = 1kp/cm' = 0.981 bar = 98066.5

kp/cm'

N/m'

Pressure mWS Pa 1mWS = 9806.65 Pa = 9806.65 N/

(gas, liquid) Torr bar 1Torr = 1.333224mbar

mmHg 1mmHg = 133.322

= 133.322N/m'

Mechanical

N/m'

1N/m' = 1Pa

stress kp/mm' Pa 1kp/mm' =

9.81

Nimm'

N/mm'

Energy, work, quantity kpm J 1J = 1

1kWh = 3.6MJ 1kpm =

9.81

hp/s

of heat cal kWh 1cal =4.1868J

Torque kpm

1kmp =

9,81

hp kW 1kW =

1000W

1 Nm/s = 1J/s

Poweroutput kpm/s Nm/s 1

= 736W = 75 kpm/s = 632 kcal/h

kcallh 1kW = 1.36 PS = 102 kpm/s = 860 kcal/h = 0.239 kcalls

Viscosity dynamic P Pas 1Pas = 1

/m' 1P =

0.1

Pas = 1g/cms

kinematic St m

'/s

= 1Pas m

1St = 1cm'/s = 0.0001 m

'/s

deg oe

273.15 K

Temperature oe K 1grd = 1°K= 1K = l °e (temperature difference)

°K

Electriccurrent A A 1mA = 0.001 A

1000A

Electricvoltage V V 1V = 1W/A 1

= 0.001 V

lMV

=10

·V

Electricresistance Q Q 1 Q = 1VIA = I /S

Magneticflux M Wb

,Vs

1Wb = 1Vs 1 M = 10-8 Wb

Magn

icfluxdensity G T 1T = Wb/m' 1G = 10-Q

Magnetic fieldslrength

= 1N/Wb 1

'/4"

Light intensity HK

lcd

= I .

107HK

1HK = 0.903342

Illuminationdensity sb

cd/m'

1sb = 10

'cd/

Illumination intensity

Ix 1

= 10' lx

00-07.0

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Conversion table

From To Multiplyby

metricsystem: British (Imp.)/USsystem: conversionfactor:

Length

Millimetres mm Inches

0.039

Centimetres cm Inches

0.394

Metres m Feet ft 3.281

Kilometres km Miles mile 0.621

Area

Squarecentimetres cm2 ISquareinches· . . 2

sq.in, ln 10.155

Volume

Cubiccentimetres cC,cm3 ICubic inches . . 3 0.061cU.in,in

Litres I Fluid ounces (US) USfl.oz 33.813

Fluid ounces (Imp.) Imp. fl.oz 35.195

Pints(US)

USpt

2.113

Pints(Imp.) Imp. pt 1.760

Quarts (US)

USqt

1.057

Quarts (Imp.)

Imp.qt

0.880

Gallons(US)

USgal

0.264

Gallons(Imp.) Imp.gal 0.220

Weight

Kilogrammes

IPounds

12.205

Pressure

Bar bar Poundsforce/square inch psi (lb.f/

2) 114.504

Pow

Kilowatts kW Horsepower hp

341

Torque

New10n

metres Nm IFootpounds ft.lb 10.723

Speed

Kilometres/hour km/h IMiles/hour mile/h (mph) 10.

621

Metres/second m/s Feet/second

281

Consumption

Litres/kilometre 1/100

IMiles/ga

on (US)

le/gal (US) 235.

value

1/100 km

Miles/gallon (Imp.) mile/gal (Imp.) 282.48

valuein

1/100

Miles/pint(US) mile/pt(US) 29.40

value

1/100 km

Miles/pint(Imp.) mile/pt (Imp.) 35.30

value in1/100km

Weightperunit power

Kilogrammes/kilowatt kg/kW IBrake horsepower/ton bhp/ton (US) 1216.55

value

kg/kW

Brakehorsepower/ton bhp/ton (Imp.) 1362.55

value

kg/kW

87 00-09.0

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Conversion table

From To Multiplyby

British (Imp.)/US system: metric system: conversion lactor:

Length

Inches

Millimetres mm 25.400

Inches

Centimetres cm 2.540

Feet ft Metres m 0.305

Miles mile Kilometres km 1.609

Area

Square inches . . 2

sq.ln,

Squarecentimetres cm2 6.452

Volume

Cubic inches . . 3

.ln,

Cubiccentimetres

ce,

cm3 16.387

Fluid ounces (US) USIl.oz Litres I 0.030

Fluid ounces (Imp.) Imp.ll.oz Litres I 0.028

Pints (US)

USpt

Litres I 0.473

Pints (Imp.) Imp.pt Litres I 0.568

Quarts (US)

USqt

Litres I 0.946

Quarts (Imp.) Imp.qt Litres I 1.137

Gallons (US) USgal Litres I 3.785

Gallons (Imp.) Imp.gal Litres I 4.546

Weight

Pounds

Kilogrammes

0.454

Pressure

Pounds force/square inch psi (lb.l/

2) Bar bar 0.069

Power

Horsepower hp Kilowatts kW 0.746

Torque

Foot pounds

b Newton metres

Speed

s/hour mile/h (mph) Kilometres/hour km/h 1.610

etlsecond ft/s Metres/second m/s 0.305

Consumption

es/gallon (US)

le/gal (US) Litres/kilometre 1/100

235.21

mile/gal

Miles/gallon (Imp.) mile/gal (Imp.) Litres/kilometre 1/100

282.48

value

mile/gal

Miles/pint (US) mile/pt (US) Litres/kilometre 1

29.40

value

le/pt

es/pint (

p.) mile/pt (

p.) Litres/kilometre 1/100km 35.30

value

mile/pt

Weightper unit power

Brake horsepower/ton (US) bhp/ton (US)

logrammes/ki

watt kg/kW 1216.55

bhp/ton

Brake horsepower/ton (Imp.) bhp/ton (Imp.) Kilogrammes/kilowatt

/kW 1362.55

bhp/ton

00-10.0

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