БМВ bmw r60

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Operation and Inspection

Operating Controls at a Glance

1. Clutch Lever2. Instrument Cluster containing Speedometer and Odometer, Tachometer, Oil Pressure

Indicator Light, High Beam Indicator Light, and eutral Indicator Light.!. Turn Signal Indicator Light". Ignition and Light S#itch

$. %ront Bra&e Lever

'. (immer S#itch, Horn Button, and Passing Light %lasher). Steering (amper

*. %or& Loc&, the +or& loc& &e also operates the loc& o+ the dual seat

-. %uel %iller Cap

1. Turn Signal S#itch and Starter Button11. Throttle /rip Tensioner

12. Throttle /rip

Fig. 1

1

12. %uel Petcoc&

1!. 0ir %ilter Housing1". Cho&e Lever 1$3$4

1$. 5ic& Starter

1'. /ear Shi+t Lever1). Center Stand 66 Side Stand

1*. %oot Bra&e Lever

1-. Li+ting Handle

2. (ual Seat Loc&21. (ual Seat elease Button

22. ear Spring Tensioner

2!. %olding Passenger %oot ests

1

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Fig. 2-4

2

!

"

2

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Instrument Cluster

1. High Beam Indicator Light, Blue

2. Speedometer #ith Odometer!. Batter Charging Indicator Light, ed

". eutral Indicator Light, /reen

$. Tachometer'. Oil Pressure Indicator Light, Orange

Figure 5

$

Ignition and Light Switch

Pull protective slide cover +or#ard and insert ignition &e and push it do#n.osition 1 o! Ignition "e#$The Ignition is s#itched on. The charge indicator sho#s that

the 7atter is ade8uatel charged.

osition 2 o! Ignition "e#$The ignition and headlight are s#itched on.

osition % o! Ignition "e#$The ignition and the par&ing lights are s#itched on. 9hen

pulling the &e out +rom this position, the par&ing lights #ill sta on. Figure &

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'immer and Signaling Switch

Position 1: High Beam

Position 2: Lo# BeamPosition !: Passing Light %lasher, spring loading automaticall returns s#itch to Position

2.

S#itch (epressed: Horn Figure (

)

Steering 'amper

B turning the stering damper &no7 clocise the +riction damper #ill prevent the +or&

+rom 7eing turned #hile the motorccle is par&ed or transported.

)urn Signal Switch* Starter +utton

Position 1: Indicates le+t turnPosition 2: Indicates right turn

S#itch (epressed: Starter 0ctuation

Friction Loc, !or )hrottle sseml#

The throttle grip is sel+ closing. 0 cruising setting can 7e attained 7 turning the set scre#o. ! clocise. Figure /

*

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Fuel etcoc,

Position 1: %uel Petcoc& ;open;

Position 2: %uel Petcoc& ;closed;Position !: %uel Petcoc& ;eserve; Figure 0

-

ear Suspension 0d

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From Starting to iding

3hen engine is cold*depress 7oth car7uretor tic&lers 2 seconds longer as the time at

#hich petrol is coming out o+ the over+lo# 7ore o+ the +loat 7o#l lo#er part =odels $3$ and '3$4 or open cho&e as +ar as possi7le, never use intermediate position =odel

)$3$4.3hen engine is hot*do not actuate tic&lers or cho&e.

For starting*turn on ignition> red, green and orange indicator lights must 7e on.

'epress starter utton.I+ ou start manuall depress &ic& starter 7rie+l and then &ic&

through +orce+ull, onl at #arm engine eventuall turn on throttle slightl ma?. 13"turn4. I+ engine )$3$4 does not start #hen it is ver hot, put cho&e +or short time on

medium position, throttle closed.

t low outside temperatures*cran& engine #ith &ic& starter t#o or three times, #ith

ignition s#itched o++> actuate starter +or no longer than 1 seconds to protect the 7atter.0 second attempt at starting #hich might 7ecome necessar should 7e made onl a+ter a

short pause o+ 2 to ! seconds, and it must not 7e o+ much longer duration than the +irst

one. starter protection switchprevents unintentional repeat starting #hile the engine is

running> This protection s#itch is actuated 7 the alternator. Onl i+ the engine P= is

su++icient +or the alternator to produce current #ill the starter loc&. Please avoid restartingthe engine 7e+ore it has stopped completel so that no damage #ill 7e done to the teeth o+

the +l#heel or the starter pinion.

3hen the engine has startedand the idle speed increases, the oil pressure indicator light

orange4 and the charging indicator light red4 in the instrument cluster must go out. I+ theoil pressure control lamp lights up #hile driving, declutch immediatel#and turn o++ the

ignition. I+ the engine oil level is ade8uate, consult our B=9 dealer. I+ the charging

indicator light stas on during operation consult our B=9 dealer. This is an indication

that our alternator is not #or&ing, and #ill ultimatel result in a dead 7atter.Letting the engine idle !or etented periodsis harm+ul since this #ill cause the engine

to overheat. %or =odel )$3$, s#itch o++ the cho&e latest #hen engine starts +aultconcentric running.

)o start riding*disengage clutch, depress +oot shi+t lever neutral indicator lamp, green,

goes out4, release clutch slo#l and appl a little throttle at the same time. Properoperation o+ the clutch increases its li+e> there+ore, avoid popping the clutch in at high

P=.

)o shi!t intosecond, third and +ourth gear, declutch and simultaneousl release the

throttle, pull up +oot shi+t lever once per gear, then let in clutch and appl throttle as

needed. Figure 11

11

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)o shi!t down+rom +ourth into third, second and +irst gear, declutch and depress +oot

shi+t lever once per gear and let in clutch.

)o go to neutral+rom +ourth, third or second gear #hen the motorccle is standing still,disengage clutch and shi+t to +irst 7 depressing the shi+t lever repeatedl and then ;pull

up; the shi+t lever partiall green neutral indicator lights up4.

0 tip: Letting the clutch slip lightl +acilitates do#n6shi+ting #hile the motorccle isstanding still. Figure 12

12

)o par, the motorc#cle*push the center stand do#n #ith our right +oot so that 7oth

roll6o++ 7rac&ets are on the ground. Put our +ull 7od #eight on the +oot pedal o+ the

center stand and pull the motorccle up and 7acards 7 the li+ting handle, &eep ourle+t hand on the handle7ars to sta7ili@e the motorccle. Figure 1%

+rea,-in -- +ut ow6

Aven the most care+ull machined parts re8uire a certain 7rea&6in period. The

per+ormance and longevit o+ our motorccle depends to a great e?tent on ho# care+ull

it is 7ro&en in. The surest method is to:1. ever e?ceed the permissi7le ma?imum speed in each gear

2. ide mostl on #inding countr roads> avoid turnpi&es!. I+ turnpi&es cannot 7e avoided, tr to var our speed constantl> do not operate at a

constant speed +or long periods.

". 0l#as approach the ma?imum allo#a7le speed and immediatel 7ac& o++.

$. The ma?imum allo#a7le P= up to ' miles is "> +rom ' miles to 12 milesit is $.

'. 0void rude 7ra&ing up to ! miles, especiall at high speed. Other#ise the 7ra&e pads

#ont get a good a7rasion value in the +uture.

1!

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ead# to ide

Fuel$%or per+ect operation the =odels '3$ and )$3$ re8uire the use o+ a 7rand6

name high test +uel #ith a minimum octane rating o+ -- O4. The =odel $3$ can 7eoperated #ith regular gasoline, #ith a minimum octane rating o+ -2 O4. In the event

ou are +orced to use gasoline #ith a lo#er octane rating, ou can prevent detonation 7&eeping the Angine P= a7ove 2$, 7 shi+ting do#n earlier than usual and 7 turningthe throttle ver slo#l.

7ngine Oil$9e recommend chec&ing the oil level regularl. (uring the 7rea&6in it

should 7e chec&ed ever ! miles. To top up al#as use the same 7rand and tpe, +illonl to the upper mar& on the dip stic&. Too much oil in the Angine is useless and ma

cause damage. The amount o+ oil 7et#een the t#o mar&s on the dip stic& amounts to 2.1

pints. The oil level must never 7e 7elo# the lo#er mar&. Dnder no circumstances open

the +iller cap #hile the engine is runningE Push the dip stic& in #hen chec&ing, do not

scre# it in. Figu re 14 1"

I! #ou desire to switch to a di!!erent rand o! oil* do so onl# i! #ou change the oil as

well as the !ilter.

Our engines are designed to operate #ith all high grade, 7rand name engine oils> the do

not re8uire an additives. %or tpes o+ recommended oil see Technical (ata.The same applies to transmission, rear #heel drive, and drivesha+t housing.

)he econom# o! operationo+ our motorccle is in+luenced to a great e?tent 7 the #a

it is operated. High speeds, +ast starts, and 8uic& stops cause, 7esides greater +uel and oil

consumption, more rapid #ear o+ tires, 7ra&es, and all po#er train parts.

*
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'ri8ing haits$ever allo# the engine P= to 7e too lo#. 0l#as engage the ne?t

lo#er gear, especiall #hen going uphill. (o#nhill, the engines 7ra&ing e++ect ma 7e

increased even more 7 shi+ting do#n to the ne?t lo#er gear> 7ut in doing so thema?imum P= allo#ed must not 7e e?ceeded. ever ride in neutral #ith the clutch

depressed or, #orse et, #ith the ignition s#itched o++.

Principall, use 7oth 7ra&es simultaneousl +or all 7ra&ing6operations and 7ra&e so+tl 66#hich means increase the pull or the pressure on the 7ra&e levers graduall so that the

#heels #ill never loc&, i+ at all possi7le. 0l#as shi+t to neutral #hen stopping. (o not

let the engine idle in gear #ith the clutch disengaged. iding the clutch or letting it slip+or long periods o+ time causes local overheating and unnecessar #ear.

0l#as turn o++ the ignition #hen stopping the engine and close the petcoc&s #hen

standing still +or longer periods.

)ra8el reparations9e recommend ta&ing along the +ollo#ing spare parts #hen ta&ing longer trips: one air

+ilter cartridge, one set o+ spar& plugs and light 7ul7s, clinderhead and clinder 7ase

gas&et, some scre#s and nuts =' F =*, spring #ashers, ting #ire, ru77er 7ands appr..2; #ide, cut o++ +rom motorccle or auto tu7es4 one pneumatic tu7e al#as replace

punctured tu7es4. Should ou o#n a motorccle #ith considera7le mileage, #e suggest

ou 7ring it to a B=9 dealer to have it chec&ed thoroughl. Be+ore going on a trip it is

important to chec& the +unctioning and condition o+ the light and ignition sstems, theclinderheads, clinders, pistons, clutch, 7ra&es, control ca7les, car7uretor, #heels and

tires. I+ an repairs are necessar the should 7e accomplished 7e+ore ou start on our

trip.I+ a trip is intended to ta&e several months and also cover countries #ith di++icult travel

conditions, it is recommended to add the +ollo#ing to the alread mentioned spare parts:

a set o+ ignition points, a centri+ugal spar& advance, and a set o+ control ca7les, to 7e

attached parallel to the ca7les in the ccle #ith adhesive tape.

Ser8icing

Servicing should 7e per+ormed, i+ possi7le, onl 7 an authori@ed B=9 dealer.

Tool 5it supplied #ith the motorccle.

1$

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=inor

Service=a

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allen #rench si@e *4, let old oil run out and scre# drain plug 7ac& in tightl, #atch +or

per+ect tightness. I+ the oil +ilter shall 7e rene#ed during the oil change, at +irst dismount

+ilter and then drain oil.

Figure 1&

1'

)otal capacit#$".2 pints F .$ pint #hen oil +ilter is changed.

Oil le8elto the upper mar& on the dip stic&, never higher, see+igure 1".

)#pe o! Oil$See Technical (ata

eplace Filter Cartridgeever ! miles #hen changing engine oil. emove cover

a+ter unscre#ing the three allenhead scre#s allen #rench si@e "4. Dnscre# he? head

scre# #rench si@e 1)4, la aside #ith +ilter cover and o6ring. Pull out +ilter cartridge#ith thin #ire hoo&s and install ne# +ilter cartridge #ith ne# gas&ets. Figure 1(

1)

emo8e oil pana+ter the +irst 1 miles 7 unscre#ing the allen6head scre#s allen

#rench si@e $4, clean thoroughl including oil screen and reinstall #ith a ne# gas&et.

11
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Figure 1/

1*

Ser8icing Item 2$ ear Swing rm +earing

Chec, !it o+ the rear #heel s#ing arm 7earing ever 12 miles 7 pulling the s#ingarm 7ac& and +orth +irml, hold on to the li+ting handle #ith our le+t hand #hile pulling

the s#ing arm #ith our right hand. Figure 10

1-

ead

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Figure 2

2

/rease rear #heel s#ing arm 7earing #ith grease gun> use grease gun #ith tapered head.

Figure 21

21

Ser8icing Item %$ +ra,e and Clutch 9oints* )hrottle

Grip

/rease:oints o+ the +oot 7ra&e item $4and o+ the clutch lever item 14+igures $!3$"ever ! miles #ith grease gun.

Lu7ricate the !ittings o+ the ca7les +or the clutch and the +ront #heel 7ra&e ever !

1!
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miles. %or this purpose, unhoo& the clutch ca7le at the clutch lever, unscre# the 7ra&e

ad

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Ser8icing Item 4$ +atter#

Chec& ever ! miles, 7ut at least once a month, #hether the acid level o+ the 7atter is

#ithin the level mar&ings o+ the acid level #indo#. I+ the level is too lo#, +ill #ithdistilled #ater not acid4. The top o+ the 7atter should 7e &ept clean and dr. Protect the

terminals against corrosion #ith grease.Caution; (o not let acid and lead o?ides o+ the terminals touch our clothes. (o notapproach the 7atter #ith an open +lame6danger o+ e?plosion.

I+ the motorccle #as not in use +or a longer period o+ time, the 7atter should 7e

recharged once a month in order to prevent the plates +rom sul+ating. Batter capacit,

see Technical (ata.

Caution; %or recharging, remove the 7atter ca7les not #hen engine is running4,

other#ise there is the danger that the voltage pea&s generated 7 the charger #ill destro

the diodes.

Ser8icing Item 5$ )ransmission* oil le8el -- oil change

Chec& oil level ever ! miles and op up i+ necessar #ith a 7rand6name oil o+ the

same tpe to the lo#est thread o+ the +iller opening> to do this, unscre# the +iller plug

#ith an allen #rench #rench si@e *4 ma&e certain +iller plug is su++icientl retightened.

Figure 24

2"

1$
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Oil Change$ Change oil a+ter engine has reached normal operating temperature, once a

ear, unscre# oil drain plug #rench si@e 1-4 and then oil +iller plug allen #rench si@e

*4. 0+ter the old oil has drained, replace the drain plug tightl. %ill #ith ne# oil. Figure

25

2$

mount o! oil appro?imatel 1.) pints

Oil le8el lo#est thread o+ the +iller opening

)#pe o! oil name67rand hpoid gear oil S0A -

Ser8icing Item &$ 'ri8e sha!t ousing* Oil le8el -- oilchange

Chec& oil level ever ! miles #ith motorccle par&ed on the center stand. To do this,

remove the +iller plug. Insert a pin into the +iller opening deep enough to touch the drivesha+t. emove and chec& the oil level, it should 7e .* inches a7ove the drive sha+t.

Top up #ith name67rand oil o+ the same tpe> i+ necessar, retighten +iller plug #rench

si@e 1)4. Figure 2&

2'

1'

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Change oil #hile oil is at normal operating temperature, ever ' miles, 7ut at least

once a ear. Dnscre# oil drain plug and then oil +iller plug each use #rench si@e 1)4.

0+ter old oil has drained, scre# drain plug 7ac& in tightl. %ill #ith ne# oil. Figure 2(

2)

mount o! oil appro?imatel .2) pints.

Oil le8el .*; over clutch cup #ith motorccle par&ed


Ser8icing Item ($ ear 3heel 'ri8e* Oil Le8el -- Oil

Change

Chec& oil le8elever ! miles and, i+ needed, re+ill to the lo#est thread o+ the +iller

opening see arro#4 #ith name67rand oil o+ the same tpe> retighten +iller scre# #renchsi@e *4 #ith allen #rench. Figure 2/

2*

1)

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Change Oil #hile oil is at normal operating temperature, ever ' miles 7ut at least

once a ear. Dnscre# oil drain plug #rench si@e 1-4 and then oil +ilter plug allen

#rench si@e *4. 0+ter the oil has drained, replace drain plug tightl. %ill #ith ne# oil.

Figure 2/ mount o! oil appro?imatel .$ pints

oil le8el lo#est thread o+ +iller opening


Ser8icing Item /$ )elescopic For, -- Oil Change

ever ' miles, 7ut at least once a ear.

A?tend telescopic +or& completel #ith motorccle par&ed on the center stand. emove

ru77er caps +rom the 7ottom plugs o+ the +or& legs, unscre# he? nuts #rench si@e 1!4#hile holding the internal he? #rench si@e "4 o+ the damper tu7e ends. Figure 20

2-

Dnscre# cover caps on top #ith pin #rench +rom tool &it4 to 7leed the +or& tu7es.

Figure %

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1*

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Pull do#n 7oth +or& legs, let oil drain. Scre# in 7ottom nuts, +ill #ith ne# oil. Initial

+illing capacit 2*cc per +or& leg, a+ter draining, re+ill capacit 2'$cc.

)#pes o! oil$ Shoc& a7sor7er oil Shell 0ero %luid ", Shell "1, Castrol B=9 shoc&a7sor7er oil or BP OLAG HL 2"'! 0ero6Hdrauli&4. Se=eig: O2 %&.4&.&2

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To do this, remove the steering damper &no7, also the upper cap and loc& #asher.

(ismount head light 7ut do not disconnect, let it hang do#n 7ut protect it and the +ender

#ith rags. emove the right handle7ar clamp 7 removing the t#o he? nuts #rench si@e1!4> loosen le+t handle7ar clamp. emove clamp 7olt +rom clamp ring allen #rench si@e

'4. Loosen centering nut #rench si@e !'4 #ith 7o? #rench +rom tool &it4. The steering6

head pla can no# 7e ad i+ properl ad

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d:ust the !oot ra,e7 turning the #ing nut at the end o+ the 7ra&e rod to the right

until the rear #heel 7arel starts 7ra&ing. Then 7ac& the #ing nut o++ !6" turns.

Caution; I+ there is too little +ree movement, the 7ra&e could loc& during operation.

Figure %(

!)

)he clutch is properl ad

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Insert throttle slide = 5 ma&e certain that the locating ta7 o+ the cover is placed properl into the

recess o+ the housing.

Insert 8acuum piston = (5#ith diaphragm and needle valve #ithout oil> place the

locating pin o+ the diaphragm so that it +its into the corresponding recess o+ the upper parto+ the car7uretor. The t#o pressure e8uali@ation holes in the vacuum piston must 7e

positioned near the 7utter+l. The upper diaphragm housing has to 7e positioned in such a#a that the ca7le ad

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%or +inding the most +avora7le petrol mi?ture turn idle air scre# 1 care+ull in either

direction. The correct mi?ture ad

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Caution66 the +uel tan& should never 7e completel empt o+ +uel so that the gas&et #ill

not dr out.

Ser8icing Item 1%$ Spar, lugs

Chec& the spar, plug electrode gap#ith spar& plug gage ever ! miles and 7e+ore

installing ne# spar& plugs. I+ necessar, ad

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Chec& the 7rea&er contact gap ever ! miles: %irst remove 7attar ca7le, then remove

the generator cover 7 removing the three allen6head scre#s #rench si@e $4. I+ no d#ell

angle meter is availa7le, proceed as +ollo#s: emove spar& plugs, insert ' mm allen#rench into the alternator rotor 7olt and turn engine clocise in direction o+ rotation

until 7rea&er lever li+ts o++ +ull. I+ necessar, contacts can 7e cleaned #ith a contact +ile>

ho#ever the 7est practice is to replace them. Chec& contact gap #ith +eeler gage .1" to.1';. To ad

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Test lamp must light up #hen the ;S; mar&ing at the +l#heel coincides #ith the #indo#

mar&ing as the engine is turned clocise direction o+ engine rotation4 66 +l #eights at

rest4. Figure 4(

")

The ignition timing ma +luctuate 7et#een the le+t and the right clinder a ma?imum o+

2o#hich corresponds to .1; o+ the +l#heel diameter4. =>Put timing light 7et#eenspar& plug cap and spar& plug and direct light against the +l#heel peripher in the

#indo# #ith the engine running. 0t idling speed o+ the engine ' to * P=4, the

+l#heel mar&ing ;S; late spar&4 must appear in the #indo# as a 7right line> i+ the 7rightline is a7ove center, the spar& is too +ar advanced, i+ 7elo# center, the spar& is too +ar

retarded. B increasing the engine P= the ;S; mar& #ill disappear to#ard the top

movement starts appro?. at * P=4 until the +l#heel mar&ing ;%; advanced timing4appears in the #indo# +rom 7elo# at ! P= +ull advance4.

d:ust timing$Loosen the t#o slotted scre#s 1 in the 7rea&er 7ase plate. Turning the7ase plate in the direction o+ rotation retards the timing> turning it against the direction o+rotation advances the timing direction o+ rotation o+ cran&6sha+t and cam6sha+t is the

same4. 0+ter completion o+ ad

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9hen chec&ing the ignition timing #ith a test lamp, turn the engine appro?imatel "$o

against the direction o+ rotation 7e+ore test test lamp goes out4. This #ill eliminate an

possi7le lost motion. echec& timing #ith timing light. I+ the timing is incorrect, chec&trueness o+ sha+t ma?. .*;4 and ease o+ travel o+ the cam o+ the centri+ugal advance

unit on the sha+t.

Ser8icing Item 15$ C#linder ead @uts Aal8e Clearance

=with 7ngine cold>

Chec& the tor8ue o+ the nuts o+ the +our clinder head nuts and the t#o clinder head nuts

ever ! miles. %irst remove the he? nut #rench si@e 1"4 as #ell as 7oth lateral nuts#rench si@e 14 and remove roc&er arm cover. Figure 40

"-

I+ necessar, retighten clinder head nuts and nuts as sho#n on diagram #ith tor8ue

#rench 2$ F 2.* l73+t4. Figure 5

$

!

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Chec, 8al8e clearance 66 re8uired a+ter each retightening o+ the clinder head nuts 66

#ith +eeler gage 7et#een valve stem and roc&er arm #hen engine is stopped and cold. To

do this, unscre# spar& plugs and turn engine over #ith allen #rench #rench si@e '4 atthe alternator rotor 7olt until the clinder to 7e ad

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Ser8icing Item 10$ )ighten nuts an olts

The correct tor8ue o+ the +ollo#ing nuts and 7olts is to 7e chec&ed ever ! miles.

@ame 3rench SiBe

1. 0?le nut +ront and rear, tor8ue !2.$ l73+t. 22 mm2. Angine mounting scre#s, +ront and rear 1- mm

!. Hose clamps:

a4 Telescopic +or& top and 7ottom74 car7uretor

c4 Bet#een drive sha+t and transmission

". Tightness o+ roc&er arm cover1 ? cap nut 1" mm

2 ? he? nut 1 mm

$. %inned e?haust pipe nuttighten #hen engine is cold4 Hoo& 9rench

Ordering o.!!*32

'. Shoc& a7sor7er mounting rear top and 7ottom4 1) mm). =u++ler suspension 2 scre#s #ith he?agonal recessed holes $ mm

each clamp,

2 he?agonal cap scre#s 1! mm*. %uel petcoc&s to tan& 2" mm

-. Angine to transmission, 1 nut 12 mm

! scre#s #ith he?agonal recessed holes ' mm1.Timing chain cover to engine,

- allen cre#s $ mm

! allen nuts $ mm

Ser8icing Item 2$ )est ide* Final Inspection

0 test ride is to 7e ta&en a+ter ever service to chec& the motorccle +or sa+e operation.

9atch in particular +or proper +unctioning o+ the 7ra&e and the ease o+ operation o+ thesteering.

%inal inspection includes chec&ing the condition o+ the tires, the air pressure in the tires,

and the proper +unctioning o+ the lighting and signal sstem.

'iagram o! Luricating oints

!2

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Figure 5%

1. %iller hole, rear #heel drive

2. (rain hole, rear #heel drive!. %iller hole, drive sha+t housing

". (rain hole, drive sha+t housing

$. /rease +itting, +oot 7ra&e lin&age'. /rease +itting, right hand s#ing arm 7earing

). =ain +lo# oil +ilter

*. Oil drain, telescopic +or&

-. Throttle assem7l1. Bra&e lever pivot

11. Oil dip stic&, engine

12. Oil drain, engine

1!. %iller hole, transmission1". Oil drain, transmission

1$. /rease +itting, clutch lever1'. Clutch lever pivot

1). %iller hole, telescopic +or&

Figure 54

!!

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3hat to do when ...

emo8ing and reinstalling the !ront wheel

1. Put motorccle on center stand.

2. emove a?le nut ) #rench si@e 224 and #asher.!. Dnscre# upper stop nut ' o+ the 7ra&e plate tor8ue arm ! #rench si@e 1!4,

holding the allen6head scre# #rench si@e '4 #ith an allen #rench, pull tor8ue

arm ! +or#ard.". Loosen a?le clamping scre# 2 #ith allen #rench #rench si@e '4. Pull out #heel

a?le $ #ith mandrel.

$. Pull #heel +or#ard slightl, ta&e 7ra&e anchor plate " out o+ #heel hu7, remove#heel.

eassem7le in reverse order. Clean and lightl grease the #heel a?le 7e+ore inserting it.

Pump the telescopic +or& several times 7e+ore tightening the a?le clamp 7olt 2 in order to

avoid 7inding o+ the +or& legs.Figure 55

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emo8ing and reinstalling the rear wheel

1. Put motorccle on center stand. 2.Dnscre# a?le nut 2 #rench si@e 224 and put

aside together #ith #asher. Loosen clamp 7olt #rench si@e 1!4, pull out #heel

a?le 1 #ith mandrel over the inclined plane. !.Pull #heel o++ to#ard the le+t s#ingarm and pull out to#ard the le+t rear. ".eassem7le in reverse se8uence. Clean

and lightl grease a?le 7e+ore inserting it into the #heel. otate #heel #hile a?le

is 7eing pushed in. Tighten clamp 7olt last. The hole in the head o+ the a?le

should 7e hori@ontal.

!"

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Figure 5&

$'

)ire Changing

)o remo8e the tire, de+late, push the tire +rom the rim in#ard. Dnscre# valve nut, push

valve into tire. O7serve the sa+t notches in the rim. Push the tire 7ead into the rim #ell

on the side opposite the sa+et notches and start li+ting the 7ead o++ the rim on the side o+the sa+et notches #ith the tire irons. emove tu7e and completel remove tire +rom

#heel in the same manner. Figure 5(

$)

)o mount the tire, push the tire 7ead into the rim #ell on the side opposite the sa+etnotches> the red point o+ the tire should 7e in height o+ the valve. Li+t the tire over the rim

+lange step 7 step, #ithout using +orce, and uni+orml on 7oth sides #ith the help o+ the

tire irons, appl talcum po#der. Insert tu7e and secure valve #ith the loc& nut> do nottighten loc& nut> turn it on "6$ turns> in+late slightl. Push the second 7ead o+ the tire over

the rim into the rim #ell, again +irst on the side opposite sa+et notches> in doing so, the

valve must 7e pushed 7ac& until the sa+et nut ma&es contact. Proceed to push the tire

7ead over the rim +lange #ith the tire irons. In+late tire, ma&e certain that the chec& linehas an e8ual distance +rom the rim edge over its entire circum+erence on 7oth sides.

!$

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Balance tire. Figure 5/

$*

ead Light +uls* +uls !or ControlLights, Speedometer Lighting, and )urn Signalsshould e replaced as !ollows

Dse scre# driver to pr the headlight rim o++ the head light. emove 7ul7 holder +romre+lector. To remove 7ul7 +rom holder, push it in and t#ist and then #ithdra#. 9hen

re+itting the 7ul7 holder ta&e care that the locating ta7 o+ the holder lines up #ith the

recess on the re+lector. Figure 50

$-

emove the par,ing light ul+rom the re+lector through the 7ul7 holder opening. (o

nottouch the re+lector sur+ace. ll soc,ets !or the control lights and the speedometer

lightingcan 7e #ithdra#n +rom their receptacles. The 7ul7s can 7e removed 7 pushing

them into the soc&et #hile simultaneousl turning them to the le+t.

Caution; )he charging indicator lightred4 must 7e lit #hen the ignition s#itch iss#itched on. The charging o+ the 7atter during operation depends upon the charging

control light #or&ing properl> use onl a 12 " 9 7ul7. Pull +lasher +rom its soc&et.9hen reassem7ling, place head light insertinto the top o+ the edge o+ the head lighthousing, push it against the head light housing at the 7ottom ma&ing certain that the

locating ta7 is properl positioned. 0scertain that the holding springs are +ull engaged.

'isasseml# o! turn signals and tail

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the le+t, +rom the center o+ the lo#er cross, rising to the right to the hori@ontal line o+ the

upper cross 1'132+eet4 and then +alls o++. Figure &2

'2

7ngine rolems* Causes and Corrections

1.7ngine does not start or starts

poorl#

Cause emed#

%uel tan& empt %ill tan& %uel petcoc& closed Open petcoc&

Throttle grip turned on too +ar #hen

engine is coldClose throttle grip

0ir +ilter clogged Clean air +ilter cartridge or replaceit

Lea&ing or clogged +uel line Stop lea& in line or 7lo# it out

(e+ective +loat needle eplace needle valveClogged idling

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2. 7ngine starts* ut idles irregularl#

Car7uretor set too rich or too lean ead

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9hen ou put our motorccle 7ac& into operation, drain the anti6corrosion oil and +ill

#ith ne# oil, see Technical (ata.(o not +orget to put the main +lo# oil +ilter 7ac& into

the engine. %ill the gas tan&. Put the 7atter 7ac& in, connect the ca7les, tighten nuts andappl terminal lu7ricant to the 7atter terminals. Clean the spar& plugs, chec& and, i+

necessar, correct their electrode gap. Lu7ricate the spar& plug threads lightl #ith

graphite lu7ricant prior to scre#ing them 7ac& in.

Speci!ications

1. Engine

The engine in the $3$, '3$ and )$3$ is an air6cooled, t#o6clinder, +our ccle

spar&6ignition engine.The engine housingis designed as a one6piece tunnel housing, rein+orced 7 internal

gussets> it accomodates the cran&sha+t and the camsha+t.

)he one-piece cran,sha!tis drop6+orged steel. /reat rigidit is achieved 7 ampl

dimensioning the main the also serve as oil return tu7es. The

clinder is sealed to the engine housing #ith a com7ination aluminum +i7er gas&et, and tothe clinder head #ith a metal6as7estos gas&et.

The aluminum allo c#linder headis care+ull +ined and e8uipped #ith shrun&6in valve

seats +ine pearlitic gra iron +or the inta&e, high allo gra iron +or the e?haust4. The

valve guides are press6+itted.9ith the clinder interposed, the clinder head is connected to the engine housing 7

+our through67olts. In addition, t#o 7olts connect the clinder head directl to the

clinder. 0ttached to the through67olts are, at the same time, also the roc&er arm 7loc&s.

"1
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o7li8ue, lead to the annular groove o+ the clinder +rom #hich the clinder #all is

lu7ricated. The connecting rods are lu7ricated through holes in the cran&sha+t, receiving

their oil +rom the annular groove o+ the +ront or rear main 7earing sleeve. The rearcamsha+t 7earing is lu7ricated directl 7 the oil pump. The timing chain dips into the oil

sump and splashes oil over all parts inside the timing cover.

The cran,case 8entilationis accomplished 7 guiding the +umes against the direction o+rotation o+ the cran&sha+t, through a settling cham7er in #hich the oil mist can separate to

a chec& valve. %rom there it is introduced into the inta&e.

3. Carburetors

Concentric !loat Caruretor

?odels 5

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)he 8acuum t#pe caruretor with

utter!l# =?odel (5

The model )$3$ is e8uipped #ith t#o Bing vacuum tpe car7uretors #ith a !2 mm

throat #ith concentric +loat 7o#l. The car7uretors are inclined and +le?i7l attached to the

clinder head through a ru77er sleeve and t#o clamps. The +uel enters the +loat housing *#here it is &ept at a constant level a tall times through a plastic dou7le +loat 1! #hich

actuates the +loat needle valve - through a pivot. The +loat 7o#l is vented in 2 places.

?ain :et s#stem

The +uel reaches the air inta&e throat 7 passing through the main

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transmission cover. 0+ter the clutch hand lever is released, the clutch lever is returned

into its initial position 7 a spring 11.

5. Transmission

)he !our-speed transmissionis mounted directl to the engine housing. The

transmission permits changing the gear ratio to permit the engine to operate in idle P=ranges at all times. The transmission consists essentiall o+ an input sha+t, counter sha+t,and output sha+t, all three o+ #hich are carried +ront and rear in over6rated 7all 7earings>

and o+ the shi+ting mechanism. The input sha+t has in +ront, the drive gear and in the rear,

the gear to actuate the &ic&starter. The clutch push rod is located inside the input sha+t.

The drive gear is mounted #ith a cushioning device to a7sor7 shoc&. The counter sha+tand output sha+t have " gears each #hich are constantl meshed.

Shi+ting is accomplished 7 pushing the +oot shi+t lo#er up or do#n. 0 segment gear

turns the shi+ter cam plate #hen the +oot shi+t lever is actuated> The 2 shi+ter +or&s areengaged in slots provided in the cam plate and into sliding dogs. The 2 dogs engage into

the appropriate gear. The 2 dogs have ) #indo#s #hich engage into ) corresponding

do#els on each gear. The dogs are splined on the ha+t and move a?iall 7et#een 2 gears,there7 engaging them. To prevent the gear +rom slipping out the cam plate is spring

loc&ed #ith a pa#l.

In neutral, a contact pin mounted on the shi+ter cam plate closes a circuit, the green

indicating light in the headlight instrument cluster lights up, indicating neutral.

")

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"*

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6. Frame

The dou7le loop tu7ular +rame made o+ oval tu7es o+ great strength is o+ #elded

construction. In the area o+ the steering head, the transom tu7es intersect the spinal tu7e.This permits a certain longitudinal elasticit o+ the steering head #ithout a++ecting the

ver great torsional rigidit. =oreover, the tunnel +or the +uel tan& can 7e &ept vershallo#.

)he rear portion o! the !rame*a ver light triangular structure, is 7olted to the dou7le

loop tu7ular +rame and is readil detached.

)he passenger !oot restscan 7e +olded. The are ad

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$. The telesco%ic &ront &or'

The +or& stem o+ the telescopic +ront +or& turns in t#o tapered roller 7earings to assure

rigid +rictionless mounting #ithout pla. 0n upper steel +or& o&e and a lo#er +orged

aluminum +or& o&e hold the hard chrome plated steel +or& tu7es. The aluminum +or&

legs slide up and do#n on the +or& tu7es. The shoc& a7sor7ers are +astened into the7ottom o+ each +or& leg. The shoc& a7sor7ers thus slide inside the +or& tu7es. 0 no@@le is

scre#ed into the 7ottom o+ each +or& tu7e. These no@@les provide damping on e?tension

#hile cali7rated holes in the shoc& a7sor7er itsel+ provide damping on compression. 0nimportant role is plaed in this process 7 the damper cham7er located 7et#een the

hdraulic piston scre#ed onto the shoc& a7sor7er tu7e and the damping no@@le. The valve

attached on the 7ottom o+ the hdraulic piston closes the damper cham7er on e?tensionin tension4 so that oil must +lo# through the damper no@@le and opens it under

compression so that the oil can escape through the cali7rated holes in the damper tu7e

and return +rom the spring cham7er into damper cham7er. Since the outside diameter o+the damper tu7e is tapered conicall at 7oth ends, the damper no@@le provides +or a

hdraulic stop in the lo#est and highest +or& position. 0 valve at the lo#er end o+ the

shoc& a7sor7er tu7e prevents the +or& tu7es +rom

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commensurate #ith the load. 0s soon as the vehicle is set in motion the rear suspension

due to the reverse tor8ue o+ the drive and irregularities o+ the road sur+ace #ill pump

itsel+ up to the correct level. 0+ter traveling a short distance the pressure rises in the highpressure portion o+ the unit due to this pumping action so that the motorccles rear

structure is raised to the normal level> regulating holes prevent continued raising. 9hen

the load is removed +rom the motorccle, the regulating holes provide +or pressuree8uali@ation to the in+lation pressure o+ the unit. The #or&ing media used in the Boge

ivomat are shoc& a7sor7er oil and nitrogen.

Caution the high +illing pressure is li&el to cause accidents as the Boge leveler isopened. epairs should 7e le+t e?clusivel to the ma&er.

emoved Boge levelers should 7e stored a7solutel in vertical position> other#ise danger

o+ de+ects.

1). *ual seat

The dual seat +lips open +rom the right revealing the tool &it and tire pump. It can 7e

loc&ed and utili@es the same &e as the steering loc&.The dual seat is not independentl sprung so as not to inter+ere #ith the care+ull

7alanced +ront and rear suspension. It has a thic& +oam ru77er cushion.

11. The +heels

The #heels have aluminum allo sa+et drop center rims #ith a provision to prevent the

tire +rom dismounting in case o+ rapid de+lation. " straight spo&es each connect the rims#ith the +ull6hu7 7ra&e drums. T#o e?actl ad

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the three6phase alternator ! driven 7 the cran& sha+t

the centri+ugal spar& advance #ith 7rea&er ", driven 7 the camsha+t

the diode plate 1 mounted a7ove the three6phase generator

the condenser 2,

and the +ollo#ing electrical components located underneath the tan&: rela $ to prevent repeat starting

voltage regulator ',

starter ),

t#o ignition coils *>

in addition there is the 7atter located underneath the tool 7o?, the t#o spar&

plugs and the lighting, signaling, and monitoring sstems. Figures &% and &4

'! '"

$!

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)he three-phase alternatorconsists o+ a rotor running in the stator housing and

mounted at the +ront end o+ the cran&s ha+t on a taper. The energi@ing current o+ the

alternator is supplied via t#o slip rings. 0ttached to the +ront cast ring o+ the stator is thecar7on 7rush holder #ith t#o plug connections. Opposite this there is a strip #ith three

plug connections +or the current ta&e6o++. 0lread during a +ast idle the three6phase

generator delivers po#er thus assuring a su++icient po#er suppl, even under increasingloads. The current +lo#ing through the charging current control lightserves to pre6

energi@e the three6phase generator> i+ there is no de+ect in the electrical sstem, the

charging current control light goes out #hen the idle speed is increased.

)he diodesat the diode plate 1 provide +or the recti+ication o+ the three6phase current+urnished 7 the generator. 0 mechanical contactor ' is used as a 8oltage regulator

mounted underneath the tan& to the spinal tu7e o+ the +rame.

)he centri!ugal timing ad8anceprovides +or the advance o+ the spar& timing #hen

speed increases.

)he rea,erinterupts at a predetermined moment the primar circuit o+ the ignitioncoils. This induces the *,$ 66 1! volts in the secondar #inding o+ the ignition coil

necessar to ignite the +uel6air mi?ture. The primar

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64/75

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65/75

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68/75

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neutral, green 12 3 2 9

charging control, red 12 3 " 9

turn signals, +ront and rear t#o each, am7er 12 3 21 9tail light and license plate light, dou7le

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stop light, 7ul7 12 3 21 9

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c. Head light lo# 7eamd. Par&ing light

e. Ca7le connector

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h. Instrument illumination

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&. eutral indicator light green4

l. Batter charging indicator light red4

2. (immer s#itch!. Turn signal, +ront, right

". Hand 7ra&e stop light s#itch

$. Turn signal, +ront, le+t'. /round connection on +rame +or ignition coils

). ela +or repeat start prevention

*. Horn-. Contact 7rea&er

1. Ignition coils

11. Condenser

12. eutral indicator light s#itch1!. Oil pressure indicator light s#itch

1". %oot 7ra&e stop light s#itch

1$. (iode plate

1'. Spar& plugs #ith caps1). Three6phase alternator

1*. Plug connection in #iring harness1-. Turn signal, rear, right

2. Tail light

a. ear light and license plate illumination

7. Stop light2. Turn signal, rear le+t

!. oltage regulator

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8/12/2019 BmW R60

70/75

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71/75

Ser8icing

Please have all the maintenance procedures laid do#n in the O#ners =anual, pages 1'66

!1,carried out regularl 7 an authori@ed B=9 dealer, and ma&e sure that the #or&done is con+irmed 7 ru77er stamp and signature in the appropriate spaces o+ pages )2

and )!. These details must 7e availa7le 7e+ore an guarantee claims can 7e considered.Be+ore ou receive this vehicle +rom our dealer he #ill have carried out a !ree pre-

deli8er# chec,.These is a schedule o+ the volume o+ the inspection #or& on page )$.

Per+ormance o+ that inspection #or& is veri+ied on page )". 0+ter the !ree ser8icesat !

and 1 miles, and commencing at speedometer reading ! miles, alternate =inorService and =a

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!. Chec& valve clearance, ad

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74/75

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)ightening torDues

S#ing arm mountingto rear #heel ).2 F 1.$ l73+t

Centering nut teles6

copic +or& *) F ).2 l73+tClinder head nuts 2$ F ! l73+t

0?le nut +ront and

rear !2.$ F 2 l73+tClamp scre# +or

#heel a?le +ront 1'.' F 2 l73+t

Clamp scre# +or

#heel a?le rear 11.$ F 1.$ l73+tHe?. nut +or oil drain

telescopic +or& 1'.' F 2 l73+t

%inned e?haust

pipe nut 1"".' F 1" l73+t

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