Engine Systems:
Detailed coverage of the BMW boxer twin-cylinder engine, including top-end overhaul (cylinder heads, valves, pistons), bottom-end components (crankshaft, connecting rods, bearings), lubrication system (oil pump, oil cooler, filtration), cooling system (air-cooled), and timing system (pushrods, lifters, timing gears).
Fuel System:
Comprehensive coverage of fuel delivery, including carburetor tuning and rebuilding (likely Bing carburetors), fuel tank and lines, fuel pump operation (if applicable), and emission control systems.
Ignition System:
Details on the ignition system components, including spark plugs, ignition coils, ignition control unit (CDI or electronic ignition), timing adjustments, and troubleshooting.
Transmission And Drivetrain:
In-depth procedures for the gearbox (5-speed), including clutch operation and adjustment, gear selection mechanisms, output shaft, driveshaft, and final drive (shaft drive) maintenance and repair.
Suspension And Steering:
Detailed instructions for front suspension (often BMW's Telelever or conventional telescopic forks depending on specific sub-model/year) and rear suspension (monoshock or twin shock absorber systems, Paralever swingarm), including fork seal replacement, shock absorber servicing, steering head bearing maintenance, and wheel bearing checks.
Brakes:
Coverage of the braking system, including front and rear brake caliper servicing, hydraulic system maintenance (fluid bleeding, line replacement), brake pad replacement, and rotor inspection.
Electrical System:
Extensive electrical schematics, wiring diagrams, component testing procedures for the battery, charging system (alternator, voltage regulator), starter motor, lighting system, instrumentation, and auxiliary electrical components.
Bodywork And Chassis:
Procedures for body panel removal and installation, frame inspection, seat servicing, and minor bodywork repairs.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, brake adjustments, chain lubing (if applicable to specific models), tire pressure checks, and general inspection points.
Troubleshooting:
Systematic diagnostic procedures for common starting issues, running problems, electrical faults, and braking system concerns, often with flowcharts and symptom-based guidance.
Engine Rebuilds:
Detailed step-by-step instructions for major engine overhauls, including piston ring replacement, valve lapping, camshaft replacement, and bearing clearance checks.
Transmission Overhaul:
Procedures for gearbox disassembly, inspection of gears and shift forks, bearing replacement, and reassembly.
Suspension Servicing:
Fork oil changes, seal replacements, shock absorber servicing, and steering bearing adjustment/replacement.
Brake System Repair:
Bleeding procedures, caliper seal replacement, pad and rotor replacement, and master cylinder servicing.
Electrical Diagnostics:
Testing of charging system components, ignition timing checks, wiring harness repair, and troubleshooting electrical accessories.
Special Tools:
Lists and descriptions of specific tools required for various repair procedures, ensuring correct execution.
Depth:
Comprehensive, covering basic to advanced repair and overhaul procedures. Suitable for both DIY enthusiasts and professional mechanics.
Diagnostic Capability:
High, includes detailed troubleshooting guides and technical data for component testing.
Rebuild Scope:
Full engine and transmission rebuild capabilities, suspension component overhauls, and electrical system repair.
Torque Specifications:
Includes detailed torque specifications for all critical fasteners, essential for correct assembly and safety.
Oil Change Engine:
Typically every 5,000 - 10,000 km or annually. Check manual for specific intervals.
Valve Adjustment:
Recommended every 10,000 - 20,000 km, especially important for the OHV boxer design.
Brake Fluid Change:
Typically every 2 years.
Engine Oil:
SAE 20W-50 or 10W-40 (depending on climate and manufacturer recommendation). API SG or higher.
Gearbox Oil:
API GL-5, SAE 80W/90 hypoid gear oil.
Brake Fluid:
DOT 4 or DOT 5.1 (check specific model requirements).
Common Wear Items:
Clutch wear, fork seal leaks, valve guide wear, charging system component failures (rectifier, alternator), output shaft seal leaks.
Fuel System Maintenance:
Carburetor synchronization and jet cleaning, petcock seal issues.
