Feature: 40 years of BMW motorcycle production in Berlin

The BMW motorcycle plant in the Berlin district of Spandau is turning 40 in 2009, during which time nearly 1.9 million motorcycles have come off the production line.

And, no, the band Spandau Ballet didn't originate from Spandau, as it's a British band - and has just reformed after 19 years.

That's for a music forum to discuss, but following is a history of the plant.

AIRCRAFT ENGINES TO MOTORCYCLES
Berlin-Spandau became a BMW AG production plant back in 1939. Up to that time the plant had belonged to Siemens & Halske, which back then had built its new aircraft engine production facility where the BMW plant is today, producing famous engines such as the Sh-14a radial power unit for the famous German Bücker 133c "Jungmeister" aerobatics biplane.

In 1936 the Siemens Aircraft Engine Plant was transformed into the independent company Brandenburgische Motoren Werke GmbH, which also built aircraft engines now under the name "Bramo". In 1939 Bramo became part of BMW AG and served until the end of the war as the production plant for BMW aircraft engines, including the nine-cylinder radial power units for the legendary Junkers JU 52.

After the war the plant in Berlin-Spandau - like other factories and production facilities in Germany - was dismantled by the Allies. But in May 1945 some 100 employees at the plant were already producing various utensils for daily use, and after the currency reform the Berlin plant began to build tools for BMW AG in Munich.

Production of motorcycles components for the BMW's main plant in Munich started in 1949 as the first step in gradually moving motorcycle production from the River Isar in Munich to the River Spree in Berlin. And as of 1958, BMW car components were also built to an increasing extent in Berlin-Spandau.

BMW Motorrad started out back then with three new models in the market: the 32hp R 50/5 intended especially for the authorities such as the police' the R 60/5 very popular among touring riders with its 42hp engine, and, ultimately, the R 75/5 featuring a 50hp flat-twin for sporting riding dynamics, a top speed of 175km/h or 109mph, and outstanding sales success in the international market.

With the motorcycle - which, in the 1960s, had been almost forced out of the market by the automobile - starting to regain popularity in the early 1970s, production figures at BMW plant Berlin began to increase rapidly. In 1970 no less than 12,287 units came off the production line and by July 1973, when the /5 model series reached the end of production, a significant volume of 68,956 motorcycles had left the Berlin Plant, production increasing five-fold within just three years.

Another highlight celebrated at the time was the completion of the 500,000th BMW motorcycle in the history of the company.

The new /6 model series upgraded in numerous features and, as a particular highlight, the legendary BMW R 90 S, were presented on the occasion of the 50th anniversary of BMW Motorrad in autumn 1973.

Displacing 898 cc, the flat-twin power unit featured in this most powerful BMW by far delivered maximum output of 67hp, sufficient for a top speed of 200km/h (124mph) and very sporting riding dynamics, without missing out on the alround and touring qualities so typical of a BMW.

RAPID GROWTH - FROM 0 TO 100,000 IN SIX YEARS
The 100,000th BMW built in Berlin-Spandau came off the production line in January 1975, the famous BMW Boxer flat-twins reaching a new level of development just one year later marked by the introduction of the /7 model series.

Apart from the R 60/7 and the R 75/7, BMW Motorrad also introduced the R 100/7, living up to the general trend to build larger motorcycles with a full litre engine capacity. And launching the R 100 RS, BMW also presented the world's first production motorcycle with full fairing able to reach a top speed of 200km/h (124mph) with its 70hp engine, while at the same time offering protection from wind and weather never seen before.

This new model series again achieved outstanding success in sales, making it imperative to enlarge the plant in Berlin-Spandau. A new assembly hall was therefore built to expand the production facilities, construction work starting in a symbolic ceremony in the presence of Walter Scheel, at the time the President of the Federal Republic of Germany. The purpose of the DM 200-million investment is to build up to 60,000 BMW motorcycles a year in Berlin-Spandau from now on, creating new jobs in the process.

In 1978 BMW Motorrad again enlarged its model range through the introduction of the R 100 RT, a full-fairing motorcycle closely related to the R 100 RS, but focusing fully on the needs of the touring rider in terms of aerodynamics, ergonomics and comfort. At the same time the so-called "small Boxer Series" makes its entry into the market in the guise of the R 45 and the R 65, once again boosting both production and sales figures.

The BMW Motorcycle Plant in Berlin-Spandau also helped to use synergies within the BMW Group, taking over the production of brake discs for BMW cars in 1979 as another major activity.

BERLIN-SPANDAU: INNOVATION IN TECHNOLOGY AND SUPERIOR QUALITY
The 250,000th BMW motorcycle built in Berlin came off the production line in 1980 - a special machine built for the palace motorcycle escort of King Hussein of Jordan. In the same year Rolf Witthöft brought home the European Offroad Championship on an 800cc BMW, and shortly thereafter the R 80 G/S made its debut with relatively modest 50hp engine output.

Combining innovative suspension technology weighing just 186kg, the R 80 G/S offered outstanding qualities not only in off-road riding, but also in everyday use and as an ideal partner on motorcycle tours.

A particular innovation hitting the headlines at the time is the single swinging arm or BMW Monolever on the rear wheel. The biggest enduro motorcycle at its time in terms of engine size set the foundation for a brand-new segment in the market -- the large-capacity grand touring enduro.

Yet a further milestone in the history of BMW Plant Berlin-Spandau was the introduction of the new BMW K Series with its water-cooled straight-four power unit fitted flat within the frame and featuring fuel injection for the first time. This new machine also marked the start of the new assembly line and the new machining shop, a massive investment serving to integrate modern industrial production facilities in the buildings protected by the government as national monuments.

Seeking for ongoing innovation in technology, BMW Motorrad subsequently launched the BMW K1 in 1988, a truly outstanding machine offering a whole range of highlights in technology. This was the first production motorcycle from BMW to feature four valves per cylinder, maximum output of 100hp and sophisticated aerodynamics providing a top speed of 240km/h.

The most important feature, however, was the introduction of ABS anti-lock brakes for the first time ever on a motorcycle as a world-first achievement. To this day, in fact, BMW Motorrad remains the leader in riding safety also through the use of sophisticated ABS technology.

To an increasing extent BMW motorcycles not only have an excellent reputation worldwide in terms of quality, riding dynamics and comfort, but also make a substantial contribution to the image of the BMW brand. Many celebrities enjoy 'Sheer Riding Pleasure' on a BMW, US actor Peter Fonda, for example, very well known to motorcyclists at the latest after his famous film Easy Rider, visiting the BMW Plant in1990 on the occasion of his 50th birthday.

THE 1,000,000TH BMW COMES OFF THE PRODUCTION LINE
Just one year later the 1,000,000th BMW motorcycle came off the production line in Berlin-Spandau, with the production of BMW motorcycles in Berlin in the course of the last 22 years now exceeding the mark of 500,000 units.

The introduction of a fundamentally new design and construction principle following the concept and configuration typical of BMW marks the 70th birthday of the BMW Boxer in 1993, the 90hp BMW R 1100 RS making its debut with a top speed of 215 km/h and full fairing to the benefit of the rider. The flat-twin power unit now came with chain-driven crankshafts positioned halfway up the engine, four valves per cylinder, and fuel injection.

To this day this construction principle sets the foundation for all BMW Boxers.

The R 1100 RS also introduced outstanding innovations in terms of its suspension and running gear, becoming the world's first production motorcycle to feature the Telelever, a ball-joint longitudinal arm fork separating the spring/damping functions, on the one hand, from the process of wheel guidance, on the other, and thus clearly standing out from the conventional telescopic fork. Indeed, this opened up a new dimension in terms of response and smooth handling, at the same time ensuring very well-balanced brake performance with automatic anti-dive.

The new Boxer series again proves highly successful, BMW Motorrad building and selling more than 50,000 motorcycles for the first time in 1995. A large number of these machines are BMW GS models consistently developed not only in technical terms since their introduction in 1980 and therefore acknowledged the world over as "the" grand touring enduro.

The last BMW with the "old" flat-twin engine came off the production line in 1996, the R 80 GS Basic concluding the highly successful chapter of BMW's two-valve Boxers after 27 years of production.

FOCUSING ON THE FUTURE: INNOVATIONS AND INVESTMENTS
In the years to come, not only motorcycles, but also production conditions continue to shape the destiny of BMW plant Berlin. A new, environmentally friendly paintshop, for example, was opened in 2004, followed by the introduction of environmentally friendly one-way and recyclable motorcycle packaging just one year later.

The first version of BMW Motorrad's new, fourth model series - the F 800 GS - came off the production line for the first time in 2006, featuring a water-cooled straight-two power unit (the parallel-twin) and setting the foundation for future models with this drive concept.

Also in 2006 BMW plant Berlin for the first time built more than 100,000 BMW motorcycles within one calendar year.

The 500,000 BMW bearing the famous model designation "GS", a BMW R 1200 GS, came off the production line on May 12, 2009, with production of the new BMW S 1000 RR, the first superbike from BMW Motorrad, also starting this year.