BMW R 60/6, R 75/6, R 90/6 & R 90 S Service Manual, 1973–1976

Published by Bayerische Motoren Werke AG, Customer Service Department, this English-language factory workshop manual covers the BMW R 60/6, R 75/6, R 90/6, and R 90 S. Numbered repair groups and job codes organize the maintenance, diagnostic, and repair information.

PDF Search, Navigation, and Diagram Detail

Text search and wiring detail: PDF text search and embedded bookmarks are not available. Small wiring-diagram labels require enlargement, and some terminal markings remain indistinct when zoomed in.

Supplied as one printable PDF in a ZIP download, with 187 pages total, including five repeated or composite duplicate sheets. The cylinder-head tightening-sequence page also contains handwritten annotations and an added torque panel; it is already included in that total.

Boxer Engine, Drivetrain, and Electrical Service

The following selected contents outline the workshop coverage. Other documented jobs include engine-breather check-valve replacement and headlamp beam alignment.

• Engine repair: Compression testing, engine removal, cylinder boring and honing, cylinder-head overhaul, valve-guide and seat replacement, crankshaft bearings, pistons, timing drive, and oil-pump inspection.

• Clutch and drivetrain: Dry-clutch removal and inspection, gearbox disassembly and shimming, selector and kickstarter service, enclosed drive-shaft removal, and final-drive setup.

• Carburetion: Model-specific Bing slide, Bing constant-depression, and Dell’Orto accelerator-pump carburetors, with idle adjustment, synchronization, fuel-level checks, cleaning, choke service, and air-filter replacement.

• Brakes and chassis: Drum and disc brake arrangements, hydraulic bleeding, pad alignment, caliper and master-cylinder removal, fork overhaul, steering adjustment, swingarm bearings, spokes, and wheel bearings.

• Electrical diagnosis: Ignition timing, alternator, regulator, diode-carrier, and starter tests, supported by fault-finding charts and a vehicle wiring diagram with component and cable-color keys.

• Workshop references: Component-specific torque tables, capacities, clearances, wear limits, repair sizes, special-tool illustrations, and removal procedures for the fuel tank, exhaust, stands, seat, instruments, and lighting.

BMW prepared this manual for master mechanics and fitters whose practical and theoretical service training would be supplemented by its detailed workshop information.

Model-Specific Carburetors and Equipment

The carburetor coverage is divided by installed equipment. The R 60/6 uses Bing 1/26/111 and 1/26/112 slide carburetors; the R 75/6 uses Bing 64/32/9 and 64/32/10 constant-depression units. The R 90/6 uses Bing 64/32/11 and 64/32/12 units.

The R 90 S section addresses Dell’Orto PHM 38 BS and PHM 38 BD carburetors with accelerator pumps. These distinctions help match adjustment and cleaning procedures to the installed carburetors.

Front-brake coverage separates the R 60/6 duplex drum, R 75/6 and R 90/6 single-disc brakes, and R 90 S twin-disc arrangement. Steering data recognizes the U.S.-market handlebar variation. The wiring key identifies the voltmeter and clock for the R 90 S, with those instruments otherwise listed as special equipment.

Internal Engine and Drivetrain Work

Step-by-step procedures cover cylinder-head disassembly, valve-guide and seat-ring replacement, main-bearing replacement, and timing-chain work. Crankshaft measurement and thrust-washer selection accompany the endplay-setting instructions.

The timing-sprocket removal section warns that chain links can damage rivet studs during extraction, requiring chain replacement.

Gearbox repair extends to shaft removal, selector-fork orientation, and axial-clearance measurement for shim selection. Final-drive instructions explain matched crown-wheel and pinion pairs, tooth-contact checks, backlash adjustment, and crown-wheel bearing shimming.

Chassis Repair and Electrical Fault Finding

Fork inspection includes alignment checks and a warning against straightening distorted stand tubes. Wheel-bearing work includes preload checks with a torque meter. The spoke-replacement section warns that projecting spoke ends can damage an inner tube.

Electrical coverage includes the compression-indicator graph, alternator and diode-carrier test layouts, alternator and starter fault-finding charts, and the keyed vehicle wiring diagram. The charging-system tests distinguish regulator faults from alternator faults before component replacement.

Fixtures and Workshop Requirements

Factory fixtures shown in use include the BMW No. 6000 assembly stand with No. 6005/1 engine/gearbox jig, No. 269 cylinder-head thrust bridge, No. 213 timing-sprocket extractor, No. 534 clutch clamping bolts, and No. 529/1 clutch-centering arbor.

The separately referenced Special Tool Catalogue, Order No. 01 99 9 099 421, and Spare Parts Catalogue are not included. Relevant tools are illustrated within the repair procedures.

For safe workshop use, disconnect the battery ground before electrical repair, keep fuel-system work ventilated and away from ignition sources, and protect painted surfaces from brake fluid.

Examples of Bearing and Clutch Inspection Data

For the covered engines, the crankshaft main-bearing journal radial clearance is specified at 0.035–0.065 mm. The bearing tables also distinguish standard and repair-stage journal dimensions and bearing shells.

The clutch data specifies a minimum clutch-plate thickness of 4.5 mm, alongside separate checks for plate distortion and diaphragm-spring condition.