REBUILDING A 1972 BMW AIRHEAD ENGINE - START TO FINISH - FULL ENGINE RESTORATION
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- เผยแพร่เมื่อ 20 มิ.ย. 2024
- Join me in the captivating process of rebuilding this iconic BMW airhead engine, where each part seamlessly comes together.
This video will guide you through the entire engine reconstruction, starting with the main bearing installation and progressing to the cylinder heads for a comprehensive top-end sealing.
Throughout the journey, I'll share numerous insights into the BMW R60/5 engine, highlighting considerations and potential areas to be mindful of during assembly.
Whether you're looking to enhance your understanding for personal repairs or simply enjoy watching the entire rebuild for entertainment, please indulge and share your thoughts. Cheers!
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Click here to watch the disassembly video: • BMW R60/5 Airhead Engi...
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BMW Airhead Parts Source: www.euromotoelectrics.com/
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Similar Motorcycles: BMW R50/5, BMW R60/5, BMW R75/5. BMW R60/6, BMW R75/6, BMW R75/5, BMW R100/7
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#bmwmotorrad #enginerebuild #restorationto
Timestamps:
00:00 BMW Airhead Engine Rebuild Intro
00:24 BMW Airhead Engine Stand
00:43 Base Assembly Overview
02:13 Rear Main Bearing Installation Tool
03:37 Rear Main Bearing Install
04:22 Main Bearing Measurement
05:22 Thrust Bearings & Dowel Pins
07:58 Dowel Pin Installation
08:37 Crankshaft Endplay Measurement
10:56 Not Enough Endplay
11:42 Too Much Endplay
12:14 Crankshaft Assembly Install For Crankshaft Endplay
14:28 Flywheel Direction Of Installation
16:18 Crankshaft Endplay Verification
17:16 Flywheel Axial Runout
18:00 Rear Main Crankshaft Seal Install
18:47 Camshaft Parts Overview
20:54 Camshaft Assembly
22:11 Cam Tappets, Pushrods, Valve Adjustment Screws
23:32 Lubrication System
24:00 Oil Pickup
24:53 Oil Pan Installation
26:20 Oil Drain Plug
26:37 Oil Dip Stick
26:53 Oil Pump Assembly
29:48 Final Flywheel Install
30:07 Oil Passageway Plugs
30:30 Oil Canister Overview
30:50 Oil Pressure Bypass Valve Installation
32:52 Oil Filter Install
34:23 Oil Pressure Relief Valve
37:00 Oil Pressure Switch & Oil Passageway Plug
37:27 Crankcase Breather
38:00 Timing Components Overview
40:25 Crankshaft Timing Sprocket Install
41:41 Timing Chain Install / Crankshaft To Camshaft Timing
42:11 Timing Chain Masterlink
43:16 Timing Chain Tensioner
44:11 Crankshaft Grooved Bearing
45:29 Timing Cover
47:21 RPM Gauge Pinion Gear
49:10 Connecting Rod Overview
54:41 Connecting Rod Install
54:26 Engine Studs
56:06 Piston & Cylinder Overview
57:46 Piston Ring Overview / Details
59:49 Piston Ring End Gap
01:00:40 Piston Ring Install
01:02:05 Piston Install Into Cylinders
01:04:41 Cylinders Onto Engine
01:06:36 Wrist Pin Install (Gudgeon Pin)
01:07:46 Additional Cylinder Studs
01:08:00 Cylinder Head Assembly
01:10:44 Cylinder Head O-Rings & Sleeves
01:11:13 Rocker Arm Assembly
01:13:47 Cylinder Head & Rocker Arm Install
01:14:52 Cylinder Head Nuts & Cylinder Head Torque
01:16:55 Valve Clearance / Adjustment
01:19:24 Valve Covers
01:20:00 Exhaust Nuts
01:20:47 Spark Plugs
01:21:05 Alternator Install
01:22:27 Ignition Advance Unit Assembly
01:23:58 Points Plate / Points / Ignition Advance Unit
01:26:00 Starter Motor Install
01:26:53 Engine Wiring Harness (61 11 1 350 636)
01:27:51 Alternator Cover / Front Engine Cover
01:28:04 Starter Cover / Air Intake Scoop
01:28:47 Engine Identification Badge (51 14 1 257 534) - ยานยนต์และพาหนะ
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This video is the most clear,best understandable and the best angle taken video ever on youtube about an airhead engine rebuilding content!Caongratulations man and thank you for your effort.I own a '95 R 80 GS and if I could can like your video thousand times!!
Wow, thank you for your comment, Aclan!🤩 This means a lot me and I am very happy that you found this video helpful.
Your BMW R80 GS is a unicorn to many and it will only become more desirable over the years. I hope you enjoy your ride😊
Thanks again - Andreas
Wow. Andreas this isnt just a youtube video, this is a complete step by step tutorial to assemble this engine! Absolutely incredible audio, the subtle visual effects with arrows or notation is spot on. What an incredible resource for anyone building this. You sir have filmed a masterpiece. Respect.
Thanks for acknowledging all the effort that went into this video! I always try to improve my content with the means I have and I'm pleased to hear that you enjoyed this video!
This engine had come a long way to get to this point and the extra days/hours that went into this were well worth it. Thank you for your ongoing support. Cheers
Excellent video. Invaluable to a BMW Boxer engine owner who wants to rebuild their engine 👍🏻 Bravo! 👏🏻 👏🏻👏🏻👏🏻
Thank you so much, Stew! I really hope it helps everyone out there including yourself😃👍🏽 Have a wonderful Sunday - Andreas
Feels like I just watched a master class in /5 engine rebuilding. Thanks so much for this, I've really learned so much!
Absolutely thrilled to hear that you found the video insightful!😃
This won‘t be my last BMW airhead engine, so there will be more to come. If you ever have any questions, feel free to ask. Thanks for tuning in!!!Cheers
I haven‘t come across a better BMW engine assembly video yet! I‘m amazed by your skills and the tools you possess not to overlook the custom tools you managed to craft. Just incredible!
Perhaps one day I‘ll reach that level. Thanks for sharing this AMAZIINNGGGGG assembly video!!!👍🏼👍🏼👍🏼
You support is fantastic and thank you for your words! I just really hope this will help many BMW enthusiasts out there like yourself. Regards Andreas
Awesome video. I hope you get the attention you deserve for all this work and great video content.
Thanks so much, Jeff! I really hope it reaches the right people that appreciate this information, like yourself😊👍🏽
Incredible BMW airhead engine assembly video 😮😮!! Achieving this wasn't simple, but you made it seem effortless. Continue the excellent work Andreas!
Hey Matthew, thanks for your support! As you already know this assembly took longer than expected, but now that it's together, I think the wait was totally worth it. I sure will. Cheers
Please make a video of how you build the engine stand. I’m building a r60/6 and it is my first project. Big thanks for making these video’s!
I will keep this in mind for a near upload! You have yourself pretty much the same bike with a few tasteful upgrades as it's just a little bit newer than this one. I'm glad I share this with you!!
Cheers
Awesome work thoroughly enjoyed process and your skills
I'm glad you enjoyed this video, Sean! Thanks for letting me know!! Cheers - Andreas
Very fascinating and entertaining. I have truly enjoyed every episode and look forward to the next. Thank you.
Thank you very much for your feedback, Martin! This gives me a good feeling that I’m going the right direction.
There are many more videos coming soon and I will keep up the work on this R60/5 build. Cheers - Andreas
i have always loved BMW Motorcycles = air head , but never owned or got a bike permit = so i got a subaru turbo instead ! but still want a BMW airhead cycle !
Thanks for sharing your enthusiasm towards BMW Airheads! Get yourself a decent project bike, work on it to get it roadworthy and your license. It’s never too late!!😃👍🏼👍🏼
Subaru Boxers engines are just as sick and then have great reliability too (when treated correctly).
Thanks for your comment! Regards Andreas
I am so impress by the quality of your job. For tehe record, i do my first drive around the house today with my R90/6 !
Thank you so much! It’s always a pleasure to read comments from you😃
I hope your rebuild and test run went according to plan! The paint job you did looks very sharp and now you just have to wait for some warmer weather to take it out for a trip.
All the best and safe rides, Sir!🏍️💨
@WorkshopRebuild Thank you . I West to thé pétrole station tokay it Washington 15 degrés celsuis. A Google whether for à winter ! The bike is running smoothly even there is a ton of work to do
You have much better weather than I do out here! You can always improve your bike as time goes on. I am curious to see update video on your secondary channel😎
I would like to know how you built the engine stand and thanks for your content.
I see there is s lot of interest in this stand and I will look into making a dedicated video about this engine stand! Thank you for your feedback😊
Regards Andreas
Súper mega video, thanks my friend. Well done…!!!😊
Fantastic job!
Thank you so much, Thomas!😃
Great video, very detailed and the production is top notch. Thanks for posting.
Thank you for your amazing feedback! It was quite the production and my computer was struggling to keep up with it, because it was my longest video to date.
I’m glad I was able to share this with you and I hope you’ll enjoy many more videos😊 Thanks for tuning in! Regards Andreas
Amazing videos. I'm in the process of stripping down a 1980 R100. Your videos will help tremendously with my rebuild.
That engine stand is perfect. I'd happily pay for the instructions on how to build one or id buy one from you. Keep up the great work.
I have two words that make this a Great Video on rebuilding this classic BMW engine. "Consice"&" Precise" .
Thank you for sharing this comment! This video marked my longest production to date, and the editing process seemed to stretch on endlessly. However, I'm delighted with the final outcome and grateful for the opportunity to share this information with you. Regards Andreas
WOW!! Well done. I just don't know what to say. The art of building the perfect boxer motor.
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I truly want to thank you, the camera and lighting crew, video/sound editors, team of researchers, and the rest of the production staff for the untold hours of work on this portion of the project. I was expecting to see the rolling credits at the end of the video. You and your crew need a vacation!
Thank you... Chris in Richmond, Virginia.
I appreciate your continued support and it means a lot to me! The BMW boxer engine is a very well built engine by some amazing German engineers and I'm so glad I could share the assembly with everyone.
This entire video along with all my other videos were created by myself. It's not an easy task, but I guess it's just part of being a "content creator".
Thanks again and I hope to read your comments in the future. Regards Andreas
I just don't know how you can do all this on your own.
Itchy Boots does it too. It seems impossible.
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October 2021
22.000 kilometer solo motorcycle journey through Africa
th-cam.com/video/9mZ6UvbwzTw/w-d-xo.html
Super video to watch and what expertise !
I'm glad you enjoyed it and thank you for your comment! Regards Andreas
Hervorragende Arbeit šefe 👍
Wen BMW diese Videos sieht, wirst du alles für die in deutsch übersetzen müssen damit BMW deine Videos zur Schulung ihrer Mitarbeiter nutzen kan😉
Vielen Dank für das Lob, Ivan! Vielleicht wird das etwas, man weiss nie was passieren kann😎👍🏽 Grüsse aus Kanada 🇨🇦
I've watched it for the second time now, and the video was exceptionally well-crafted. You're truly a skilled mechanic!
Thank you so much! I hope you find value in this video for your own repairs. Cheers
great video. but i miss the tricky part with the front main bearing and the pin.
Thank you for your feedback, it's much appreciated! The front main bearing assembly has been covered in a separate video prior to this engine assembly video. You can see that here if you wish: th-cam.com/video/qoN5LG1IeEA/w-d-xo.htmlsi=NMpEI2jqIvICDPbf
Regards Andreas
Just an excellent video Bravo!!!
Thank you very much! Regards Andreas
I love the BMWmotorbikeand engine, I will very simple but is most reliable.
I’m glad you do and you are right, they are very reliable due to their simplicity👍🏻😃
Congrats man you did a great job and posting this will help thousands of people in the future. Quite a series you hae made! Look forward to your first putt on it, I would have used a bit of Permatex grey goop on some sealing surfaces for strength but it is a mess to get off.
Thank for always being one of the first to comment on my new videos! Your support helps more than you think!! I really hope this video proves helpful to as many people as possible in the future.
I use silicone based sealants on specific mating surfaces wihtout gaskets, but since this engine has gaskets for all surfaces I opted for aviation gasket maker. It's a much thinner product and also seals better (in my opinion). The goop is also undesireable with the silicone base products, but it's fairly easy to trim with a sharp utility knife. Cheers
I think you should consider a CD version in case anyone wants to buy one it would be a good offline back up for old guys. Would be merch people would actually need LOL! Or write a guide.@@WorkshopRebuild
I just bought an R75. I’ve never rebuilt an engine before. This looks pretty Intimidating. Should I just send it out to someone else to do or give it a shot myself, in your opinion?
Hello Andrew, congratulations on acquiring an R75! This engine is notably user-friendly, although there's a range of specialty tools required for its disassembly and assembly. If you're envisioning this engine as a long-term project, you certainly can rebuild it. However, for a truly robust engine, it might be a good idea to entrust it to an experienced BMW airhead shop.
Before proceeding, it's advisable to inquire about the cost of such an engine rebuild, allowing you to plan accordingly. It's worth noting that these classic BMW engines can become quite costly as you delve deeper into their restoration process.
I hope this helps. Best regards, Andreas
This was beautiful. HOW did you figure all this out? Did you go to a BMW R/60 college? 😂 ...or was all of this gleaned from methodical study of the service manual?
Thank you for your comment, it's much appreciated! During the disassembly process of this engine I learned how all components are put together and from rebuilding other engines, I've also gained a lot of knowledge.
I mainly use service manual specifications when it comes to rebuilding an engine to understand the manufacturers clearances and torque values. Many specialty tools used in this video are completely custom and designed to my liking in order to make this assembly work.
In the near future I will work on a custom engine setup based on a boxer engine. This will involve machine-work and fabrication work. Something I have not showcased yet, but I believe it will be a fun project to share with you.
Thanks again for your comment. Regards Andreas
I thought you were not supposed to use sealant on the oil pan I never did on my /5s never had a oil leak same with the push rod seals
Hi Scott, I would not recommend using a silicone based sealant as it does not offer any benefits between a gasket and a metal surface.
Therefore I opted for the liquid sealant which is specifically formulated to work with both materials and offer better sealing. Even though the oil pan surface was extremely flat along with the engine block mating surface, I chose this sealant so I do not have to deal with oil leaks anytime soon.
If you do not apply any sealant that is totally fine! It's well known in the BMW community that the oil pans warp due to the torquing of the oil pans bolts and when reinstalled, they do not seal as good anymore.
Thanks for your comment, Scott. Regards Andreas
Is it accurate to measure the end play, with all that mounting lube on the thrust washers? Doesn't it affect the measurement? Shouldn't you install all, measure and then lube? Comparable with wheel bearings pre-load measurement.
Hi Xavier, this is a great question and it's completely possible to verify the crankshaft endplay without oil or assembly lube. This just means after you verify the numbers you will have to remove more components to apply oil or lube again.
Luckily, before the assembly, I measured all the components to understand what thrust bearings I needed between 08:37 and 10:56. With these values, you can determine the endplay before the installation!
It turns out the measurement is exactly the same when I measured the crankshaft endplay as when I verified it with the dial gauge.
It would be interesting to hear your opinion and what you would do. Regards Andreas
Interesting info, thanks for the good content. Really learn a lot from your non-BMW approach to things. Techniques coming from general mechanic experience, just incredibly rich content.
Trying to find the vid where you discuss how you cleaned the cases and the other aluminum parts to get the finish we see in the vids
The cast aluminum parts were a lot of work and here is what I did to them:
-Cleaned parts with an industrial cleaning detergent
-Measured castings
-Covered machined surfaces
-Vapor Blasted with crushed glass bead
-Cleaned with soap & water multiple times
-Cleaned in an ultrasonic cleaner
-Prepped for Cerakote (high heat & dissipating coating)
I will try and do a full breakdown video on this for an upcoming project, but I hope this helps in the meantime. Regards Andreas
@@WorkshopRebuild Thank you Andreas. I am familiar with vapor blasting but since it uses grit, I generally do not do this with engine castings. Perhaps CO2 blasting would be a safer option.
@@rcaso9561 I would not recommend vapor blasting machined surfaces, but external surfaces are totally fine.
Cleaning with Co2 will give you good results, but it will not leave you with a “like new” finish. Discolouration and oxidation may still be apparent.
@@WorkshopRebuild Thank you Andreas. I seal my vapor blasted parts w Nyalic which is OK for anything that doesn't get hot and it resist chemicals pretty well. Especially useful for plated bolts and hardware some of which go through other parts. Alum wheel hubs also.
Unglaublich, wie kompliziert dieser scheinbar so einfach aufgebaute Konstruktion doch tatsächlich ist: Spezialwerkzeug, Hitze, genaue Messdaten, Toleranzen, Ausgleichsscheiben...und und! Typisch deutsche Technik der damaligen Zeit, bis in die 80er.
Der Gipfel der Komplexität war viel früher der Motor der NSU 250 Max in den 50ern. Von außen ganz unscheinbar, aber im Innern der komplizierteste und interessanteste Serienmotor der damaligen Zeit...aber alltagstauglich!
Auch die Vorgängermodelle OSL waren kompliziert und umständlich.
Genauso die damaligen scheinbar einfach aufgebauten BMW Motoren. Damals 250 bis 600 ccm. Siehe oben... ! Aber richtig gebaut auch alltagstauglich.
Erst Honda hat mit dieser Irrationalität Mitte der 70er aufgeräumt.
Mit der Einführung der Vierzylinder ( in den 50ern für den einfachen Motorradfahrer in Deutschland nicht denkbar) , diese Maschinen waren offenbar absolutes Hightech!
Ich habe meine CB 400 four vor jetzt 30 Jahren technisch quasi mit dem Bordwerkzeug neu aufgebaut und diese Maschine läuft bis heute zuverlässig!
Hi Andreas, Your work is fantastic as usual! I am working on my starter motor just now. i have a couple of questions regarding the starter motor cover if you can help:
1. The Fiche and parts manuals are not clear if special nuts are being used. Did you use captive nuts for the plastic cover spring? Or just wave washers under normal hex nuts?
2. Did you use some sort of a gasket under the plastic starter cover? The Fiche and part manuals show a gasket but with different shapes or not at all. If so, where/how does it fit the cover?
thanks yet again
Allan
Hi Allan, Thanks for your lovely comment and thanks again for watching another video!
The starter motor is held with two regular hex nuts and wave washers beneath them. I've only seen the gasket under the starter cover in the parts fiche and nowhere else to be honest! This gasket is not included in an engine gasket kit nor have I seen it available on website in the U.S or in Europe. This leads me to think it could have possibly been an early-model option and they might have discontinued it...but then again I'm not 100% sure!
Based on the parts fiche, the gasket would sit between the cover and the engine case. This would essentially be pressed down by the wire-strap. It would make sense to have a gasket just to protect the engine case from the plastic I suppose.
This is something I should look into and get back to you about. Once I find something out, I will send you an email, Allan.
Great question and I hope to sent you some info soon. Regards Andreas
@@WorkshopRebuild thank you; I look forward to anything you might discover. I am learning a lot following your channel A
Can I send you my R27 single cylinder motor and transmission for your treatment?
Hi there! While I'm unable to accept custom work, I'm planning to offer such services in a few months. I'll keep you posted on updates and availability. Feel free to reach out to me via email, so we can discuss further details and to stay in touch. My email address is in the description of each video.
Thanks for your interest! Regards Andreas
Why didn't you connect the 3 phase wires of the alternator, and closed off the front cover? Is there any reason for that?
Just wondering where did u get this engine repair stand I want to buy one as well for my project. Please provides so information thanks
This custom-built engine stand will soon be available as a DIY kit, complete with plans, a mounting plate file, cut list, parts list, hardware, and additional information. Stay tuned for updates!
Best regards, Andreas
@@WorkshopRebuild Thanks Andreas
Better than porn website! great job
Haha! Thank you so much🤣😆 I appreciate your support👍🏽 Regards Andreas
I was thinking the same 😂 if engineeringHub was a thing, this video would be on it!
😄👍🏽👍🏽
The flywheel looks like it is cracked.
I was waiting for this comment! The flywheel is actually not cracked. The visible lines are from applying selenium dioxide to the surface. Often times when this chemical is applied to protect steel, it's hard to get an even result when brushing it on. That's also another reason why you can see inconsistencies.
If the flywheel would have been submerged it might have turned out better, but I do not have that much product.
Thanks for pointing this out and I hope I could answer this. Regards Andreas
@@WorkshopRebuild. Thank you for the reply. I wasn't expecting that. While I have your attention... What are the mercury switches and that other stuff, located in the license plate holder for? I have never seen that in a motorcycle before.
@stanleydenning The license plate holder was a anti-theft device from back in the day. It had mercury switches on either side (Left and Right).
If you park your bike and someone would raise it, the mercury would make a connection and an alarm would go off.
Maybe I’ll clean it up and mount it back onto the bike. It’s from the same era and would be a neat feature😃
IF YOU COULD ONLY TALK FASTER. I DON'T KNOW WHAT OTHER VIEWERS SAW BUT I GOT NOTHING FROM THE VIDEO. SORRY.