BMW R90S Restoration Guide
Restoring the Legendary BMW R90S
Few motorcycles have achieved the legendary status of the BMW R90S.
Introduced in 1973 and produced through 1976, the R90S helped redefine what a sport-touring motorcycle could be. With its distinctive cockpit fairing, hand-painted pinstripes, dual-disc front brakes, and powerful 898cc boxer engine, the R90S quickly established itself as one of BMW's most iconic motorcycles.
Today, the BMW R90S remains one of the most sought-after Airheads ever produced.
At Boxer Metal, we've spent decades working with BMW motorcycles and understand the unique challenges involved in restoring, preserving, and upgrading these remarkable machines.
Why the R90S Is Special
The R90S represented a major step forward for BMW.
Notable features included:
- 898cc boxer twin engine
- Factory café-inspired fairing
- Dual front disc brakes
- Dell'Orto carburetors
- Distinctive paint schemes
- Sport-oriented ergonomics
- High-speed touring capability
The motorcycle's combination of performance and comfort helped establish BMW as a serious competitor in the sport-touring market.
Restoration Philosophy
Every R90S restoration begins with a simple question:
What is the goal?
Some owners seek a factory-correct restoration that preserves originality and collector value.
Others prefer a rider-focused restoration that improves reliability while maintaining the character of the motorcycle.
Both approaches can produce outstanding results when executed properly.
Mechanical Restoration
Mechanical reliability is the foundation of any successful restoration.
Areas commonly addressed include:
Engine
- Compression evaluation
- Top-end rebuilding
- Timing system inspection
- Oil system service
- Seal replacement
Transmission and Drivetrain
- Transmission inspection
- Clutch service
- Driveshaft evaluation
- Final drive inspection
Fuel System
The Dell'Orto carburetors are a defining feature of the R90S.
Proper rebuilding and tuning can dramatically improve performance and rideability.
Charging and Electrical Systems
Many R90S motorcycles benefit from:
- Charging system upgrades
- Improved grounding
- Electrical troubleshooting
- Modern reliability improvements
Cosmetic Restoration
The appearance of the R90S plays a significant role in its appeal.
Typical restoration work may include:
- Paint restoration
- Pinstripe preservation
- Fairing repair
- Wheel refinishing
- Hardware restoration
- Seat refurbishment
- Instrument refurbishment
Attention to detail is critical when restoring a motorcycle of this significance.
Factory Correct or Rider Improved?
Owners often face a decision between strict originality and practical upgrades.
Popular rider-focused improvements may include:
- Charging system upgrades
- Improved lighting
- Suspension improvements
- Brake enhancements
- Touring accessories
These modifications can improve usability while preserving the spirit of the motorcycle.
Common R90S Issues
As these motorcycles age, several areas deserve attention:
- Dell'Orto carburetor wear
- Charging system concerns
- Electrical connector corrosion
- Suspension wear
- Brake system deterioration
- Fuel tank condition
- Rubber component aging
Addressing these issues proactively can significantly improve reliability and riding enjoyment.
Explore R90S Projects
The Boxer Metal Gallery includes examples of BMW Airhead restorations, custom builds, and vintage BMW projects that demonstrate the level of craftsmanship and attention to detail applied to every motorcycle.
Browse the gallery to explore completed projects and gather inspiration for your own R90S restoration.
Start Your R90S Project
Whether you own a complete motorcycle, a long-term project, or a partially restored machine, Boxer Metal can help guide the restoration process.
From technical advice and parts selection to complete custom builds and restorations, we're passionate about preserving and improving BMW's most iconic motorcycles.
Contact Boxer Metal to discuss your BMW R90S project and discover what's possible.