Market Segment:
Dual-sport / Adventure Touring Motorcycles
Competitors:
Yamaha XT500/Tenere, Honda XL series, Suzuki DR series, Kawasaki KLR series of the era.
Bike Key Features:
Robust air-cooled boxer twin engine, shaft drive, long-travel suspension, capable off-road and on-road performance, iconic design.
Value For Buyers:
Essential resource for owners and mechanics to maintain, troubleshoot, and repair these classic BMW motorcycles, preserving their longevity and performance.
Systems Covered:
Engine, Transmission, Drivetrain, Suspension, Brakes, Electrical System, Fuel System, Exhaust System, Frame, Bodywork, Controls, Wheels & Tires, Special Tools, Troubleshooting, Maintenance, Repair Procedures
Bodywork Chassis:
Frame inspection and repair, fuel tank and seat removal/installation, fairing and body panel maintenance, handle bar and control adjustments.
Page Count:
Estimated 400-600 pages (typical for comprehensive workshop manuals of this era)
Manual Type:
Service and Repair Workshop Manual
Engine Systems:
Airhead boxer twin engine (R80: 797cc, R100: 979cc), cylinder head removal/installation, piston and ring replacement, crankshaft and connecting rod inspection, valve clearance adjustment, timing chain/belt inspection (if applicable for this era), lubrication system (oil pump, filter, oil passages), cooling system (air-cooled, but includes oil cooler details).
Transmission Drivetrain:
Clutch operation and adjustment, gearbox disassembly and reassembly, gear selection mechanism, driveshaft maintenance and lubrication, final drive unit (bevel gear inspection, lubrication, and seal replacement), U-joint inspection.
Suspension Brakes:
Front forks (telescopic, including seal replacement, oil change), rear shock absorbers (monolever/paralever systems if applicable for 1983 models, though typically later), swingarm bearings, brake system (front and rear drum/disc brakes), brake caliper overhaul, master cylinder maintenance, brake fluid bleeding, hydraulic line inspection.
Electrical Fuel Exhaust:
Ignition system (points, condenser, ignition coil, spark plug specifications), charging system (alternator, voltage regulator), starting system (starter motor), battery maintenance, lighting system (headlight, taillight, turn signals), instrumentation, fuel tank removal and installation, carburetor overhaul and adjustment (Bing carburetors common), fuel lines and petcock maintenance, exhaust system inspection and replacement.
Maintenance Procedures:
Routine servicing, oil changes, filter replacement, spark plug replacement, air filter cleaning/replacement, valve clearance adjustment, brake bleeding, drive shaft lubrication, battery charging/testing, tire pressure checks, general inspection points.
Repair Procedures:
Engine top-end overhaul, engine bottom-end overhaul, gearbox rebuild, suspension overhaul, brake system repairs, electrical component diagnosis and replacement, carburetor tuning, clutch replacement, wheel bearing replacement, final drive seal replacement.
Troubleshooting Guides:
Systematic approaches to diagnose common faults in engine, electrical, and mechanical systems. Includes symptom-based problem-solving.
Technical Depth:
Comprehensive from basic rider maintenance to full engine and transmission rebuilds. Includes diagnostic procedures, troubleshooting guides, exploded diagrams, and torque specifications for critical fasteners. Suitable for both novice mechanics and experienced technicians.
Torque Specifications:
Detailed torque values for critical engine, chassis, and brake fasteners essential for proper assembly and safety.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all systems, aiding in diagnosis and repair of electrical faults.
Special Tools:
Lists and descriptions of specialized tools required for specific maintenance and repair procedures (e.g., flywheel puller, fork seal drivers).
Engine Type:
Four-stroke, air-cooled, boxer-twin (flat-twin)
Engine Displacement R80:
797.5 cc
Engine Displacement R100:
979 cc
Horsepower R80:
Approx. 50 hp (37 kW) at 6500 rpm (varied by market/tuning)
Horsepower R100:
Approx. 65 hp (48 kW) at 7000 rpm (varied by market/tuning)
Torque R80:
Approx. 57 Nm (42 lb-ft) at 5500 rpm
Torque R100:
Approx. 70 Nm (52 lb-ft) at 6000 rpm
Fuel Delivery:
Dual Carburetor (typically Bing 32mm or 40mm depending on model variant)
Fuel Type:
Unleaded gasoline (premium recommended)
Bore X Stroke R80:
81 mm x 75.6 mm
Bore X Stroke R100:
94 mm x 70.8 mm
Compression Ratio:
R80: 8.2:1; R100: 8.5:1 (typical)
Oil Change Interval:
Typically every 5,000 km (3,000 miles) or annually, whichever comes first.
Valve Adjustment Interval:
Every 10,000 km (6,000 miles) or annually.
Drive Shaft Lubrication Interval:
Every 10,000 km (6,000 miles).
Engine Oil Type:
API SG or higher, SAE 20W-50 or 15W-50 recommended (consult manual for exact specs).
Engine Oil Capacity:
Approx. 2.75 liters (2.9 US quarts) with filter change.
Gearbox Oil Type:
Hypoid gear oil, SAE 80W/90 API GL-5.
Final Drive Oil Type:
Hypoid gear oil, SAE 80W/90 API GL-5.
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for specific recommendation).
Common Wear Items:
Clutch wear, swingarm bearings, driveshaft U-joints, output shaft seal leaks, fork seal leaks, regulator rectifier issues, carburetor synchronization drift.
Diagnostic Challenges:
Carburetor tuning and synchronization, electrical system troubleshooting (especially older wiring harnesses), timing adjustments on airhead engines.
