BMW R45, R65, R65 LS Motorcycle Factory Repair Manual

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Comprehensive Factory Workshop Manual for BMW R45, R65 & R65 LS Boxers

The BMW R45, R65, R65 LS Motorcycle Factory Repair Manual is the genuine BMW Motorrad service department publication designed for authorized workshop personnel and dedicated motorcycle technicians. Spanning the entire mechanical architecture of the classic horizontally-opposed twin boxer platform, this manual provides comprehensive coverage for both the 473 cc R45 (offered in 20 kW / 27 HP and 26 kW / 35 HP states of tune) and the larger 650 cc R65 (33 kW / 45 HP) and aerodynamic R65 LS models. It incorporates both early-series technical specifications and the significant 1981 model-year revisions, including updated cylinder construction, lightweight flywheel and clutch assemblies, modified crankcase breather pathways, and the shift from mechanical contact breakers to transistorized electronic ignition.

Complete Engine Overhaul and Mechanical Rebuilding

Delving deep into the heart of the air-cooled twin, the BMW R45, R65, R65 LS factory repair manual details step-by-step disassembly, dimensional inspection, and precision rebuilding procedures for the crankcase, valvetrain, and bottom end. Technicians are provided with complete measurement tolerances for cylinder barrels, categorized by standard bore groups A, B, and C, as well as factory oversize stages. Detailed procedures guide the technician through cylinder head stripping, valve guide renewal with exact thermal interference specifications (heating heads to 240°C–260°C), 45° valve seat machining angles using Hunger cutting tools, and cold valve lash adjustments (0.10 mm inlet, 0.20 mm exhaust). The bottom-end sections cover main bearing shell replacement, crankshaft journal micrometer logging across multiple planes, axial clearance shimming using color-coded thrust washers (2.483 mm to 2.673 mm thicknesses) to achieve the target 0.08–0.15 mm endplay, connecting rod alignment and twist verification, and Eaton trochoidal oil pump clearance testing.

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Engine Electrical, Transistorized Ignition & Charging Systems

Electrical service coverage in this BMW workshop manual is exceptionally thorough, addressing both early mechanical breaker systems and modern 1981+ solid-state electronics. Technicians will find complete diagnostic guidance for the Bosch 12V 0.7 kW starter motor (including bench testing without motorcycle removal, solenoid servicing, and carbon brush replacement), the crankshaft-driven 280W Bosch alternator, external diode board testing, and voltage regulator calibration. Ignition sections detail mechanical point gap and dwell adjustments, dynamic timing verification using a strobe light on the flywheel ‘S’ and ‘Z’ inspection marks, and complete diagnostic decision trees for the breakerless Hall-effect trigger unit, control unit, and twin-spark ignition coil introduced on 1981 models.

BMW Factory Tightening Torques and Maintenance Standards

Every critical fastener throughout the machine is governed by precise factory torque specifications. In addition to general DIN and BMW engineering standards (BMW N 113 49.0 and BMW N 600 02.0), this volume features a dedicated summary of tightening torques covering the engine, exhaust star nuts (200 + 20 Nm), clutch housing and flywheel expansion bolts (100 + 5 Nm), gearbox, driveshaft twelve-sided bolts, front forks, steering stem, rear axle final drive with swinging arm pivot pins, brake hydraulics, and wheel clamping bolts.

Chapters Covered

00 Maintenance and general hints

• Introduction and layout system
• Tightening torques to BMW and DIN standards (N 113 49.0 and N 600 02.0)
• Bolts and nuts DIN standards and strength categories
• Summary of tightening torques for R 45, R 65, R 65 LS
• Statutory units conversion and comparison table
• Determining oil and fuel consumption (DIN 70030)
• Engine oil viscosity temperature chart
• Engine oil circuit flow diagram

11 Engine

• Engine technical specifications (pre-1981 models: 20 kW, 26 kW, R 65)
• Engine specifications for 1981 models (including R 65 LS)
• Compression test procedure (11 00 039)
• Engine removal and installation (11 00 050)
• Cylinder removal and installation (11 11 050)
• Cylinder reboring and honing guidelines (11 11 527)
• Cylinder head removal and installation (11 12 080)
• Cylinder head stripping, valve regrinding, and assembly (11 12 513)
• Valve guides renewing and reaming (11 12 561)
• Timing chain cover detaching and attaching (11 14 060)
• Radial seal for crankshaft replacement (clutch and alternator ends)
• Engine breather hose and check valve renewal
• Crankshaft removal, journal measurement, and installation (11 21 001)
• Main bearing bushings renewal and pinning (11 21 531)
• Crankshaft endplay axial adjustment and thrust washer selection
• Flywheel and clutch housing removal and installation (11 22 000)
• Connecting rod removal, small-end bushing service, parallelism and twist inspection (11 24 000)
• Piston removal, ring end gap inspection, and cylinder bore checking (11 25 000)
• Timing chain sprockets renewal (11 31 061)
• Valve clearances adjusting (11 34 504)
• Eaton oil pump overhaul and clearance testing (11 41 000)
• Comprehensive engine troubleshooting guide

12 Engine Electrical

• Electrical specifications and component ratings (starter, alternator, regulator, diode board, spark plugs, contact breaker)
• Specifications for 1981 models (Hall transmitter, twin-spark coil, solid-state electronics)
• Exploded assembly diagrams of alternator and starter motor
• Ignition timing adjustment and point setting (12 11 004)
• Static timing on 1981 models using BMW ignition tester (12 3 650)
• Dynamic strobe timing inspection
• Ignition trigger removal and installation (12 11 060)
• Breaker points renewal (12 11 141)
• Troubleshooting trees for conventional and transistorized ignition systems
• Hall effect transmitter component breakdown
• Ignition coil removal and testing
• Control unit and heat sink replacement (12 14 010 / 12 14 025)
• Alternator, diode board, and regulator testing and overhaul (12 31 009)
• Starter motor in-chassis checking, bench overhaul, and brush renewal (12 41 009 / 12 41 020)

Together, these sections equip professional mechanics, independent restorers, and vintage BMW enthusiasts with the complete technical foundation necessary to perform showroom-grade mechanical rebuilding, faultless electrical troubleshooting, and routine factory-spec maintenance on any R-series boxer twin.

Professional Workshop Precision & Instant Digital Access

The BMW R45, R65, R65 LS Motorcycle Factory Repair Manual gives you the capability to execute everything from routine valve adjustments and ignition timing calibrations to complete engine tear-downs, crankshaft bearing refitting, and electrical system overhauls. Relying on verified factory specifications, torque tables, and assembly sequences prevents damaged threads, oil leaks, bearing failures, and improper ignition timing that lead to severe engine damage. Delivered as an instant high-resolution PDF download immediately upon purchase, this manual is completely free of shipping delays and can be saved to your computer, tablet, or smartphone for instant benchtop reference, or printed in whole or part whenever you work in the garage.