Working on a motorcycle frame can be a rewarding and challenging experience. The first is to strip the frame down to its bare bones, which you can see in my 15min Teardown video. This allowed me to assess the overall condition and decide what needed to be repaired or replaced.
Even though this frame was really healthy, I welded up two small cracks that occurred on the frame support brackets that lead to the rear footrests. Instead of sandblasting this frame I went on to remove all residue, paint and rust with a laser cleanign machine. After that the frame was ready for a brand new paintjob in order to restore the frame to its original condition.
Attention to detail is crucial when restoring a motorcycle frame to ensure the bike is safe to ride, especially when you know 50 years old!

Now for the frame assembly of the BMW R60/5 Airhead, I got as many parts ready as I possibly could. There are at least 50 parts on both tables and the two major components that are going back onto this motorcycle are the front forks and the swing arm assembly.

Mounting a fork onto a motorcycle frame requires proper alignment. The fork legs should be straight and parallel before mounting. The fork needs to be secured to the triple clamp on the frame using locking nuts, ensuring a tight fit. In this video I share the assembly process in short with the correct measurements and torque specs according to the BMW service manual.

The swing arm on the otherhand is a critical component that ensures the alignment and stability of the rear wheel of the motorcycle. The process involves carefully fitting the existing swing arm with new parts, like bearings, seals, and thrust sleeves, to then aligning the rebuilt swing arm to the frame using specialized tools. Not to forget, the driveshaft also has to be installed prior to the assembly.
As you can tell, there are a few steps you want to get right before the swing arm goes back onto the main frame. With help of this video, I hope you can rebuild your own swing arm and install it back onto your motorcycle without any issues.

If this video was helpful in any way, I'd appreciate it if you hit that like button and if you want to be one of the first to see the assembly video, be sure to subscribe!

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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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Timestamps:
00:00 BMW Airhead R60/5 Frame Assembly Intro
00:30 FRAME ASSEMBLY PARTS OVERVIEW
01:49 FRONT FORK ASSEMBLY
06:22 HANDLEBAR ASSEMBLY
07:10 MIRROR ISSUE
08:20 ENGINE MOUNTING STUDS & FOOTRESTS
09:17 REAR BRAKE PEDAL
09:33 REAR FRAME ASSEMBLY
11:16 SWING ARM OVERVIEW
14:44 SWING ARM BEARINGS and SEALS
17:15 DRIVESHAFT ASSEMBLY
20:05 SWING ARM ASSEMBLY
20:41 CENTERING SWING ARM
23:56 FINAL WORDS

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