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BMW

BMW R90 1990 All Service Repair Manual

BMW R90 1990 All Service Repair Manual

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Vehicle data plateRef 471069
Brand
BMW
Vehicle
Motorcycle
Models covered
Misc, R90
Years
1990
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

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🏷️ Basic Information
Identification
Make:
BMW
Model:
R90
Year:
1990
Codes
Vehicle Code:
R90/6, R90S (though the manual is likely for the R90/6 as the S was an earlier variant)
👋 Introduction
Market Position
Market Segment:
Premium touring/sport motorcycle of its era, known for its air-cooled boxer twin engine and shaft drive.
Competitive Analysis
Key Competitors:
Honda GL series, Yamaha XS series, Kawasaki Z series, Moto Guzzi T and V series.
Key Features
Unique Selling Points:
BMW's renowned reliability, shaft drive for low maintenance, distinctive boxer engine layout, and comfortable touring ergonomics.
Target Audience
Primary Users:
BMW R90 owners seeking to perform maintenance and repairs themselves, enthusiasts, and independent repair shops.
📋 Manual Details
Coverage Areas
Coverage Scope:
All service and repair procedures for the 1990 BMW R90 motorcycle
Page Count
Page Count:
Estimated 300-500 pages (typical for comprehensive service manuals of this era)
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Service:
Complete engine overhaul, tuning, component inspection, and replacement procedures for the R90 Boxer engine.
Fuel System:
Carburetor (likely Dell'Orto PHM 40) overhaul, adjustment, fuel pump, fuel lines, and fuel tank servicing.
Ignition System:
Ignition timing, spark plugs, ignition coils, breaker points (if applicable for the specific 1990 model year variant, though electronic ignition was common), and associated wiring.
Transmission And Drivetrain:
Gearbox disassembly, assembly, maintenance, clutch operation, shaft drive system service, and final drive lubrication.
Brake System:
Front and rear brake system servicing, fluid replacement, caliper maintenance, master cylinder overhaul, and disc/pad inspection.
Suspension And Steering:
Front fork (likely telescopic with air assistance or conventional damping) overhaul, rear shock absorber service, swingarm maintenance, and steering head bearing adjustment.
Electrical System:
Wiring diagrams, battery maintenance, charging system (alternator, voltage regulator), lighting system, starter motor, and instrument cluster.
Chassis And Bodywork:
Frame inspection, body panel removal and installation, seat servicing, and exhaust system maintenance.
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, spark plug checks, chain adjustment (if applicable, though shaft drive is more common), tire pressure checks, and general inspection procedures.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common starting, running, and electrical issues, with symptom-based fault finding.
Component Overhaul:
Detailed instructions for the complete disassembly, cleaning, inspection, repair, and reassembly of all major motorcycle components.
Recalibration And Adjustment:
Specific procedures for carburetor synchronization, ignition timing adjustments, valve clearance settings, and brake lever/pedal free play.
Specifications And Tolerances:
Precise technical specifications, torque values, clearances, and wear limits for all serviceable parts.
Technical Depth
Depth Of Coverage:
Comprehensive, covering everything from basic owner maintenance to full engine rebuilds and complex electrical diagnostics.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Likely text-searchable PDF allowing quick access to specific topics.
Print Quality
Print Quality:
High-resolution scans of original manual pages, suitable for digital viewing and printing.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, four-stroke, horizontally opposed twin-cylinder (Boxer)
Displacement:
897 cc (54.7 cu in)
Bore X Stroke:
90 mm x 70.6 mm
Compression Ratio:
9.5:1 (typical, may vary slightly)
Performance
Horsepower:
60 hp (45 kW) @ 6,200 rpm (R90/6)
Torque:
75 Nm (55 lb-ft) @ 4,500 rpm (R90/6)
Fuel System
Fuel Delivery:
Two Dell'Orto PHM 40 CD carburetors
Fuel Type:
Unleaded gasoline (Premium, 91 octane or higher)
Lubrication
Oil Capacity:
Approx. 2.5 liters (2.6 US qt)
Oil Type:
SAE 20W-50 motorcycle-specific oil (e.g., Castrol GTX or equivalent)
Cooling System
Cooling Method:
Air-cooled
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh gearbox
Optional
Optional Features:
N/A (5-speed was standard)
Features
Clutch:
Single dry plate, diaphragm spring clutch
Final Drive:
Enclosed shaft drive
Fluid Specifications
Gearbox Oil Type:
API GL-4 SAE 90 hypoid gear oil (e.g., Castrol EPX 90 or equivalent)
📐 Dimensions
Exterior
Length:
Approx. 2,180 mm (85.8 in)
Width:
Approx. 750 mm (29.5 in) (handlebars)
Height:
Approx. 1,180 mm (46.5 in) (seat height)
Weights
Dry Weight:
Approx. 200 kg (441 lbs)
Wet Weight:
Approx. 215 kg (474 lbs)
Gross Vehicle Weight Rating:
Approx. 400 kg (882 lbs)
Wheels And Tires
Front Tire Size:
3.50-18 4PR
Rear Tire Size:
4.00-18 4PR
Front Wheel Type:
Spoked, 18-inch diameter
Rear Wheel Type:
Spoked, 18-inch diameter
🛡️ Safety Features
Ratings
Safety Standards:
Compliant with relevant automotive safety standards for motorcycles of the era.
Active Features
Braking System:
Dual disc front brakes (often 280mm), single disc rear brake (often 240mm) with twin-piston calipers. ABS was not standard.
Lighting:
Halogen headlamp, tail light, brake light, and turn signals.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Analog instruments: speedometer, tachometer, voltmeter, oil pressure light, neutral indicator, turn signal indicators, high beam indicator).
Driver Assistance
Assistance Features:
N/A (No electronic rider aids like ABS or traction control were standard).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 5,000 km (1,800 - 3,000 miles) or annually, whichever comes first.
Valve Adjustment Interval:
Every 6,000 - 10,000 km (3,700 - 6,200 miles).
Spark Plug Replacement:
Every 10,000 - 15,000 km (6,200 - 9,300 miles).
Brake Fluid Flush:
Every 2 years or as recommended by the manufacturer.
Final Drive Oil Change:
Every 10,000 - 12,000 km (6,200 - 7,500 miles).
Fluid Specifications
Brake Fluid Type:
DOT 4 (or DOT 3, check specific model variation)
Final Drive Oil Capacity:
Approx. 150 ml (0.16 US qt)
Known Issues
Common Wear Items:
Camshaft and tappets (wear), output shaft seal leaks, clutch wear, electrical connector corrosion, and front fork seal leaks.
Carburetor Issues:
Difficulty synchronizing, worn jets or floats, leading to poor idle or performance.
📚 Vehicle History
Brand Heritage
Manufacturer History:
BMW Motorrad has a long history of producing reliable, technologically advanced motorcycles since the early 20th century, known for boxer engines and shaft drive.
Model Evolution
R Series Heritage:
The R90 is part of BMW's iconic R series, which began with the R32 in 1923. The R90 lineage traces back through models like the R75/5 and R60/7, culminating in the R100 series.
R90 Specific Development:
The R90 was introduced in 1973 as a more powerful successor to the R75/5, with the R90/6 offering a balance of performance and touring comfort, while the R90S was the sportier, faired variant.
Production
Production Years:
The R90 series (including R90/6 and R90S) was produced from 1973 to 1976. A 1990 reference likely indicates a manual for a later model or a vintage enthusiast market; typically R90s are 1970s models. This manual might cover general Boxer principles applicable to later models or is a misprint year for the R90 model itself.
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
The R90/6 and R90S were generally well-received for their performance, build quality, and distinctive character, becoming sought-after classics.
Ratings
Reliability Reputation:
High, known for longevity and durability when properly maintained, characteristic of BMW motorcycles.

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Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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