BMW Service - K75, K100, K1, K1100 Fuel Cap Rebuild

How to rebuild the fuel cap from a BMW K75, K100, K1 or K1100.
Music:
Song: (Live 1983) Rainbow In The Dark
Artist: DIO
Album: Dio At Donnington UK: Live 1983 & 1989
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Song: The Cutter
Artist: Echo & The Bunneymen
Album: Me, I'm All Smiles
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Song: Evening Star
Artist: Judas Priest
Album: Hell Bent For Leather
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Song: Spirit In The Sky
Artist: Norman Greenbaum
Album: Best Of Norman Greenbaum - Spirit In The Sky

[@pgrens]

That tumbler spring is a real bugger. Thanks for the walk through on that, had to watch a second time before I went back to finish her!

[@Alex-gc2su]

Hi Guys Greetings from Germany from me and my K1100RS. Perfect instructions for help and without this guide I would have failed 😉 👍

[@jawarider2243]

Just bought a european(I live in Europe) 1991 K100RS 16V for cheap, because of no start issues. After 2500$ of labour at a BMW dealer the previous owner had enough and got rid of it :) The no start issue was only caused by water in the fuel tank. Ordered a fuel cap rebuild kit, and I will have a nice K100RS soon :)

[@ChrisR.Harris]

Good deal for you, Jawa! You'll like the video material this winter.

[@ericmowrey6872]

Sweet, mine's long overdue so now I'm motivated. Did you ever work in aviation maintenance Chris? I'm a retired A&P mechanic and we routinely used petroleum jelly when fitting new O-rings to various engine & hydraulic system components...never recall seeing the same practice in the automotive/motorcycle field. You're a rare mechanic. Even your swearing is on an aviation maintenance level.

[@Batti2323]

This really helped me, Chris. My kit came with an extra washer, and I wouldn't have known it was extra without the detail you put into this. Another successful gas cap rebuild thanks to you!

[@ChrisR.Harris]

Cool Batti, thanks!

[@MrTriple3]

These videos make owning and enjoying these great (and undervalued in the market) bikes a whole lot easier. Thanks for taking the time to share your expertise.

[@smilingfox5952]

You are incredible. Your videos helped me many times to repair, service and maintain my 31 year old K100LT. Thanks from Berlin.

[@ChrisR.Harris]

Thanks! My recent offerings are over here: www.patreon.com/user?u=25101320

[@ChrisR.Harris]

Thanks Eric! While I wish I were swearing over a Le Rhone rotary engine I have no first-hand, hands-on experience with aviation maintenance. However, most of the same principles in aviation maintenance apply to long-term automotive / motorcycle care. Thank you for noticing and taking the time to comment :)

[@samaelic]

Well this also works fora R1150RT. After replacing the rubber seal few days ago, the key didn't turn like it used to do. When i saw this video, it was clear i didnt pre-load the spring. Went to my garage and a few minutes later it worked like a charm. Thanks (again) Chris for all your great videos you made ;)

[@MobtownGeorge]

Thanks guys! Watched your video and then rebuilt my fuel cap in about 10 min. It was wonderful to really see how it all goes together before I started the job.

[@ChrisR.Harris]

Thank you!

[@dcompson]

Thanks for putting all of these k videos together. Making my life so much easier.

[@ChrisR.Harris]

You're welcome, David. We just landed in Maine, setting up the shop and more videos will come soon. Thanks for following along.

[@scottjohnston664]

Thank you very much sir. Mine is now done. I had a contaminated fuel problem after heavy rain. Much appreciated. Please make more old K videos. Love my K1100LT"92.

[@ChrisR.Harris]

I'm glad the problem was minor. Much more K1100 material ahead. Take care.

[@BOC69er]

I replaced the gaskets of my K75 RT today (my BMW dealer had one last gasket kit :-) and your video was really helpful! Thank you!

[@ChrisR.Harris]

I've encountered this once. Tap on the cap to see if it will release. If not... Drill the lock cylinder out. Just drill the top and then try to remove the tumblers. Continue drilling until you get to the bottom of the lock cylinder. Then you can release the fuel cap with a flat-blade screwdriver. Good luck, Chris

[@georgelofoten7815]

Thanks a lot Chris for another great vid. Gave me some very useful clues which got me out of a mess! Cheers from the south coast of England.

[@scottjones1640]

Thanks Chris. I learn a little with every new video. I had a lot of Honda's in my younger years and I did what work I could on them. I don't mean to sound derogatorybut it seems

[@jimboknowsit]

Thanks for the good vid on fuel cap rebuild.

[@ChrisR.Harris]

At least you got it open! Replacing the lock cylinder is easy :)

[@staryjanek]

Like the "balls" comment. Reminds me of the old Royal Navy "honesty washer". When stripping down an engine, the CPO would slip an "extra" washer in among the disassembled parts, when the students were at a break. When all was back together the chief would ask, "anything" left over ?. Only the honest guys would say "Yes chief, this washer". The less than honest guys would NOT own up to this and would have "lost" the extraneous washer. Royal Navy engineering CPO's not daft you know :)

[@thomrieck]

FYI - the part number given is out of stock at most dealers (including Bob's online). However, if you call Bob's, they actually assemble the kit in house and so don't have a part number for their gasket kit.

[@ChrisR.Harris]

If you are sure that the lock is seized or not turning go ahead and drill the lock cylinder out or take the fuel tank to a good locksmith.

[@pieterbrepoels6563]

Can you change the lock of the fuel cap? How do you remove the cilinder? Thanks!

[@83226505]

Great job guys. Most useful!

[@ChrisR.Harris]

No worries!

[@staryjanek]

I had to "screwdriver" the lock, not pretty. managed to turn the cam with the screw driver in the lock and open the cap. Then I got the lack barrel out,looks like one of the pins was missing, one of the holes in the plastic cam cylinder looks pretty chewed :( Waiting for a new barrel & keys,hoping it can still turn the cam. ho hum ! cheers J

[@Garfoid]

Need the parts in the video from 03:11 to 04:00. But can't find them anywhere. Any help appreciated?

[@cyrilusek]

Thank you for sharing your knowlegde. I m gone make it my bike as well.

[@ChrisR.Harris]

Hi Scott, The K's are very reliable and low maintenance, the old Airheads are simple to work on and the Oilheads (for the most part) are fairly low maintenance and reliable. Over-engineered? Of course! Do Germans do anything simple?

[@ThePolo5569]

I can't seem to get the spring in there correctly and it's hard to see exactly what you did. Also I have this one extra piece that I didn't see you have. Can you help? Thanks

[@throsturv]

Hi Chris, and thanks for your excellent videos on K-bike repair and maintenance. Where do you buy the fuel cap repair kit? Cheers T

[@staryjanek]

Hi, love these videos. I got a problem with my K75S fuel cap NOT unlocking today when I went to refuel :( Got home ok though :) However, I can't get the key to turn at all. What next steps would you recommend ? Would drilling the lock banjax the whole cap ? I wondered about drilling through the plastic above the 4 retaining screws and freeing the whole cap mechanism ? And then getting the lock replacement from Motobins. Altogether a real PITA :/

[@scottjones1640]

BMW's are almost over engineered. Are they really high maintenance ? Also, the pliers, fuckin epic. Keep the videos going. I'm learning as I go.

[@raybrensike42]

The crazy gas we get now eats up the paint, and it makes the bike ping. I filled up with some ethanol free gas and no more ping at any time.

[@cyrilusek]

Cheers Bro!

[@ChrisR.Harris]

You're welcome.

[@TheEnergyball]

I imagine this should also keep the tank from leaking when the bike is on the side stand. When might you consider getting a new gasket set vs lubing the existing parts? Would you do that first? Thanks for sharing @Chris Harris.

[@ChrisR.Harris]

Ali S; If you can rejuvenate the old parts try that first. If it fails then just replace.

[@jiwcoronado]

i cant find a 1987 k100rt gas cap

[@denisflynn9082]

Chris, I have a key that turns but doesn't unlock the cap. It feels like the whole assembly is turning. What do you think the best approach would be to this repair? Any help or recommendations would be appreciated.

[@mikefried9699]

my local dealer, Leo"s South, says they can't get the kit or the foam washers anymore.... Options?

[@ChrisR.Harris]

Great!

[@maximusmax4557]

I found your video linked on one of the BMW parts sites, as I was shopping for a replacement gasket set. I have a customer whose K75S ran, supposedly for about 20 miles, with water in the tank, due to a "leaking gasket." I'm going to recommend a cap rebuild, as well as a replacement gasket ring. I'm also going to recommend replacing the fuel filter, as I recently read once water gets into the fuel filter, it MUST be replaced. However - and here's my question - do I need to be concerned with water in the injectors, and if so, is there an easy way to bleed them? I plan on draining the fuel tank, mopping up any water in the bottom of the fuel tank, rebuilding the cap, replacing the gasket and filter, and then trying to fire the bike. I'll also likely add the correct amount of Iso-HEET to the system, which is supposed to absorb any water and allow it to burn off inside the combustion chamber. How does any or all of that sound? Thanks in advance!

[@ChrisR.Harris]

Maximus; you've got it under control! Yes, do as you state though I'm sure you're done by now, 4 weeks later. Good job, Maximus. Stay tuned for more, Chris

[@denisflynn9082]

I was afraid that was what you were going to suggest. Where is your shop located? Thanks for the advise.

[@TheTuxMaster]

I Realy like the music a-rond 8:57!

[@OldBMWMaster]

The cap on my 1985 K 100 RS is totally different. I should have checked before I bought the kit. Anyone need a kit cheap?

[@ChrisR.Harris]

Manchester, New Hampshire.

[@ChrisR.Harris]

There ought to be a room in every house to swear in. It's dangerous to have to repress an emotion like that. Mark Twain, a Biography Under certain circumstances, urgent circumstances, desperate circumstances, profanity provides a relief denied even to prayer. Mark Twain, a Biography With all due respect 30% of my customers are female and I've never had a complaint. If my foul language is offensive to you might I suggest turning the volume off or selecting a video from someone else? Thank You

[@ChrisR.Harris]

Those 4 balls do NOT go to the fuel cap! Nice try though :) Thanks fdor the test.

[@ChrisR.Harris]

Thanks T! Buy from a BMW dealer. Part # 16 11 9 062 461 - Fuel Cap Rebuild Kit - $30.00 - Does not include the large rubber o-ring that fits between the cap assembly and the fuel tank.

[@marcellecadieux8977]

this kit is no longer available in Canada or in Germany. Had to order it from Max They still have it. 32.50$ nowadays. We'll do maintenance on Blackie's cap It's starting to act up...

[@eddisc4205]

you need three more PAIR of hands to "help" you...~~~o&o>

[@cyrilusek]

Hi,

[@alansykes39]

Only just came across all these excellent and informative vids., Chris - but your language ! D'you realise that K-bikes are sometimes owned by ladies ? ! What are you doing to the reputation of us bikers ? "Please keep the airwaves clean - nobody appreciates the obscene..."