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Thread: 1973 R75/5 Rebuild Project Journal

  1. #61
    B Reams brook.reams's Avatar
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    1973 R75/5 Rebuild, Installing New Clutch

    I got the new clutch installed this weekend. I wrote up the procedure I used to install it as a resource for others who want to see how this was done.
    • 21 1973 BMW R75/5 New Clutch Installation


    Feel free to post comments on the procedure page.

    I also made a number of updates to the page I wrote up on removing/installing the flywheel and installing a new oil pump cover and cover o-ring. I had an "adventure" with the rear thrust washer that I discovered when I was starting to install the new clutch. I got lucky and no engine damage, but I updated the write-up to help others avoid the problem I had.

    • 11 BMW R75/5 Remove-Install Flywheel, Replace Rear Main Seal, Oil Pump Cover & Cover O-Ring


    My thanks to Tom Cutter, Bob Fleischer and Anton Largiader for providing information and advice. As always, any mistakes made are my own and do not reflect on the expertise and knowledge of these folks.

    Here are a couple pictures from the write-up.

    Old (top) & New Clutch Parts
    Old (top) & New Clutch Parts, Inside to outside, Left-to-Right

    .
    Supplies and Special Tools to Mount the Clutch

    Toothpick Application of Thin Layer of Honda 60 Molypaste to Edge of Fingers of Diaphragm Spring
    Toothpick Application of Thin Layer of Honda 60 Molypaste to Edge of Fingers of Diaphragm Spring

    Clutch Diaphragm Spring Against Face of Flywheel
    Clutch Diaphragm Spring Against Face of Flywheel

    New Clutch Bolts and Long Bolts
    New Clutch Bolts Inserted and Long Bolts Ready to be Removed.

    Transmission Aligned with Engine
    Transmission Aligned and Tight to the Engine Clutch Housing
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  2. #62
    B Reams brook.reams's Avatar
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    1973 R75/5 Replace Oil Pan Gasket and Camshaft Seal

    I've completed this work on the project and posted a blog with links to how I did the work.
    1973 R75/5 Rebuild: New Oil Pan Gasket and Camshaft Seal

    Or, you can go directly to the write up of how I did this work here:


    I think I found a neat new tool for removing shaft seals and ordered it.

    Lisle_58430SealPuller.jpg

    It should arrive today and I'll be using it next time instead of the overly large adjustable oil seal puller I have been using. I'm always nervous about nicking the camshaft or seal housing and this new tool looks like it should avoid that.

    Here are a few pictures from the write up.

    Replacing Oil Pan Gasket


    Engine on Side to Remove Oil Pan
    Engine on Side to Remove Dirty Oil Pan

    Permatex Gasket Remover Soaking In
    Permatex Gasket Remover Soaking In

    \Checking Torque (72 INCH/pounds) on Oil Pickup Bolts
    Checking Torque (72 INCH/pounds) on Oil Pickup Bolts

    Clean Pan Mating Surface
    Clean & Polished Pan Mating Surface

    Clean Oil Pan with New Pan Gasket
    Clean Oil Pan with New Pan Gasket

    Replacing Camshaft Seal

    Leaking Cam Shaft Seal
    Leaking Cam Shaft Seal

    Points Plate
    Points Removed and Timing Plate Ready to Remove

    Old Seal
    Old Seal

    Driving Cam Shaft Seal
    Driving Cam Shaft Seal with 5/8 Inch Spark Plug Socket

    New Points and Allen Head M4x10 Cap Screws
    New Points and Allen Head M4x10 Cap Screws
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  3. #63
    B Reams brook.reams's Avatar
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    1973 BMW R75/5 Rebuild: Replace Alternator Brushes and Front Crankshaft Seal

    I had replaced the leaking camshaft seal earlier and you can read about how I did that here:
    The alternator has 97,500 miles on it, so I decided to replace the brushes. *I hadn't seen evidence of oil leaks from the front crankshaft seal, but it turns out its very easy to replace it when I was replacing the alternator brushes. *I also cleaned the rust and flaking paint off the starter motor and then painted it to stop any further rusting.

    You can read about what I did on both of these tasks here:
    I bought the brushes at Euro Motoelectrics which is here in Denver, CO. *I also picked up a hardened bolt to extract the alternator rotor from the tapered nose of the crankshaft.

    Rotor Puller Bolt and New Brushes
    Rotor Puller Bolt and New Brushes

    These jobs went pretty quickly and were straight forward. *I found I needed a *200/260 watt soldering iron to remove the old solder and solder the new brushes as they are soldered to a large plate that dissipates heat pretty well. *My 140 watt gun wasn't up to the task.

    New Brushes Installed
    New Brushes Installed

    Shaft Seal Puller Installed
    Shaft Seal Puller Installed With Adjustable Pivot Pin Resting on Engine Housing

    At this point, the engine work I planned is done. Here is the painted starter motor installed and the engine after polishing up the cases.

    Painted Starter Motor Installed
    Painted Starter Motor Installed

    Polished Engine
    Polished Engine

    Polished Engine
    Polished Engine
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  4. #64
    Monza Blue 1974 R90/6
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    That looks really nice and your pictures are excellent resources. Thanks for taking the time to publish.

    Barron

  5. #65
    B Reams brook.reams's Avatar
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    Quote Originally Posted by barron_williams View Post
    That looks really nice and your pictures are excellent resources. Thanks for taking the time to publish.

    Barron
    Hi Barron,

    Thanks for the kind words. More to come as I am hoping to start putting things back together again.

    Best.
    Brook
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  6. #66
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    OT I know, but must ask. Is that a fatigue mat on your shop floor? Does it really help? Been thinking about investing in one...Thanks, Ron

  7. #67
    B Reams brook.reams's Avatar
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    Quote Originally Posted by 71243 View Post
    OT I know, but must ask. Is that a fatigue mat on your shop floor? Does it really help? Been thinking about investing in one...Thanks, Ron
    Ron,

    There was an earlier question about the grey flooring I have. Here are the details:
    http://forums.bmwmoa.org/showthread....l=1#post858229

    It's not so much a fatigue mat, as a keep oil off the concrete, sound deadening, warmer floor, dropped parts don't bounce so far, kind of mat. It has held up well and I'm pleased with it.

    Best.
    Brook:
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  8. #68
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    Hey Brooke,

    I was wondering what you thought about the Niche Cycle headers that you bought for your /6?

    I bought my first /5 earlier in the year and the headers have some serious rust on them, so I'm considering replacing.

    cheers,

    Seth

  9. #69
    B Reams brook.reams's Avatar
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    Quote Originally Posted by sirsethro View Post
    Hey Brooke,

    I was wondering what you thought about the Niche Cycle headers that you bought for your /6?

    I bought my first /5 earlier in the year and the headers have some serious rust on them, so I'm considering replacing.

    cheers,

    Seth
    Hi Seth,

    I've had not any issues with the Niche products on the R75/6 "Grey Ghost". The installed correctly to the holes on the swing arm brackets without any problem. That said, the Grey Ghost is garaged and I've only added about 1,000 miles to it since I finished the build. I will say the clamp between the header and the silencer is an external ring that is pretty thick compared to the original /6 configuration. But it looks fine when the bolt/nut is rotated out of sight.

    For the current 75/5 project, I selected the Sito /5 cigar shape muffler which I sourced from Cycle Bins in the U.K. I haven't even taken those out of the carton yet (to avoid having anything bang into them ;-) ), so I don't have anything to report on them.

    Best.
    Brook.
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  10. #70
    B Reams brook.reams's Avatar
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    1973 R75/5 Rebuild, Refinishing Wheels, Fixing Spun Wheel Bearing

    Folks,

    This part of the project is done. I had Woody's Wheel Works install the new stainless steel spokes and also lube and set the preload on the bearings. The rear wheel left side bearing was spun and I decided to use a Speedi-Sleeve to repair this. Woody's installed it for me.

    Here is a short blog with links to more a detailed write-up on this work.
    • 1973 BMW R75/5 Rebuild: Wheel Polishing, Bearings and Spokes

    I also updated the main project page to include links to all the write-ups organized by sub-systems so you can quickly locate write-ups that might be of interest on your next project.

    I hope this content is helpful to others. Here are a couple of pictures from the write-up.

    Rear Wheel, Bearing Cover Side
    Rear Wheel, Hub Cap Side

    Rear Rim Gouges
    Rear Rim Has Deep Gouges

    Bolt Cutter
    Brute Force Approach: Using Bolt Cutter to Cut Spokes

    Front Rim with Cut Spokes
    Front Rim with Cut Spokes and Hub Removed

    Removing Nipple with Power Screw Driver
    Non-Distructive Approach: Removing Nipples with Power Screw Driver

    Bearing Stack, Outside (Left) to Inside (Right)
    Bearing Stack, Outside (Left) to Inside (Right): Bearing Cover & Gasket, Inner Bearing Race, Outer Bearing Race,
    Wedding Band, Inner Spacer, Outer Spacer

    Polished Hubcaps
    Cleaned and Polished Hub Caps

    Woody's Wheel Works Final Product
    Woody's Wheel Works Complete Front Wheel
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  11. #71
    B Reams brook.reams's Avatar
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    1973 BMW R75/5 Rebuild: Engine Back in the Frame

    Folks,

    The engine is back in the frame. :-) Here is the write-up on that part of the project.
    • 11 BMW R75/5 Installing the Engine In the Frame


    There is a certain satisfaction when you start seeing the parts going back together and a restored machine taking shape in the shop :-)

    Transmission is next.

    Here are a couple pictures from the write up.

    Polished Engine
    Polished Engine Ready to Install Into The Frame

    Engine In Frame Resting on Lift
    Engine Inside Frame Resting on Motorcycle Lift

    Rear Engine Mount Showing Spacers
    Rear Threaded Rod Centered Through Both Spacers

    Left Side Shackle and Side Stand
    Left Side Shackle Keeps Side Stand on Pivot Pin (Looking Toward Rear)

    Engine In Frame & Secured to Lift
    Engine In Frame & Secured to Lift
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  12. #72
    not so retired henzilla's Avatar
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    lookin' good

    We just picked up a /5 to start bringing back to running condition ...nice to see yours coming together.
    Steve Henson
    SABMWRA MOA Club#62's Flat Fixer/ current forum moderator
    It's not the breaths you take, but the moments that take your breath away-D.Dillon/G. Strait

  13. #73
    B Reams brook.reams's Avatar
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    Quote Originally Posted by henzilla View Post
    lookin' good

    We just picked up a /5 to start bringing back to running condition ...nice to see yours coming together.
    Thanks. It's comforting to see a motorcycle starting to take shape from the mound of parts :-)

    Best.
    Brook
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  14. #74
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    R75/5 Rebuild: Transmission Installation

    Folks,

    And, now the transmission is back in the frame. Progress !!!!
    Here is the write-up on how I did this part of the project. Note, I did not rebuild the transmission, but I did refinish it removing 40 years of crud.


    Next up is the rear sub-frame, rear brakes and shocks.

    Below are a couple of the pictures you'll find in the write-up

    Refinished Left Side
    Refinished Transmission Ready to Install in the Frame

    Clutch Throwout Parts
    Clutch Throw Out Assembly Parts

    Clutch Throwout Assembly
    Clutch Throw Out Assembly and Clutch Lever

    Frame Protection
    Frame Protection Before Inserting Transmission In the Frame

    Transmission Input Splines Sliding Into Clutch Plate Splines
    Transmission Input Splines (RIght) Sliding Into Clutch Plate Splines (Left)

    Clutch Throwout Rod Bearing Assembly
    Clutch Throw Out Bearing Assembly Showing Direction and Order of Insertion into Bearing Housing

    Job Done
    Transmission Install Job Done
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  15. #75
    B Reams brook.reams's Avatar
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    1973 R75/5 Rebuild: Install Swing Arm and Rear Drive

    Folks,

    I've gotten this part of the project done and documented what I did here:

    • 33 BMW R75/5 Install Swing Arm and Rear Drive


    Next up is the rear brakes and sub-frame. The parts bags are fewer and the boxes emptier :-)

    And, a couple of the pictures from the write-up.

    Rear of Transmission & Drive Shaft  Coupling (Upper Right) ]
    Rear of Transmission with Drive Shaft Coupling (Upper Right) and Frame Protection

    Powder Coated Swing Arm with Drive Shaft Inside
    Powder Coated Swing Arm with Drive Shaft Inside

    Swing Arm Pivot Pins, Lock  Nuts and Plastic Caps
    Swing Arm Pivot Pins, Lock Nuts and Plastic Caps

    Swing Arm Boot - "OB" EN (Top) on Round Section
    Swing Arm Boot - "OB" EN (Top) on Round Section

    Measuring Swing Arm Gap to Center the Swing Arm
    Measuring Swing Arm Gap to Center the Swing Arm

    Sitting on Rear Tire to Tighen Drive Shaft Bolts
    Sitting on Rear Tire to Tighen Drive Shaft Bolts

    Swing Arm and Rear Drive Installed
    Swing Arm and Rear Drive Installed
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

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