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1973 R75/5 Rebuild Project Journal

1973 BMW R75/5 Rebuild: Refinishing Headers, Headlight and Steering Damper

Over the weekend, I dove into refinishing some of the high profile parts. I documented what I did in separate web pages under the "51" category for "Vehicle Trim". There are lots of pictures showing before and after: here are the links.

<a href="http://brook.reams.me/about/bmw-motorcyle-rebuilds/1973-bmw-r755-rebuild-project/51-bmw-r755-headlight-shell-and-switch-housing-paint-repair/">51 BMW R75/5 Headlight Shell and Switch Housing Paint Repair</a>
<a href="http://brook.reams.me/about/bmw-motorcyle-rebuilds/1973-bmw-r755-rebuild-project/51-bmw-r755-restoring-header-pipes/">51 BMW R75/5 Restoring Header Pipes</a>
<a href="http://brook.reams.me/about/bmw-motorcyle-rebuilds/1973-bmw-r755-rebuild-project/51-bmw-r755-refinishing-steering-damper-knob/">51 BMW R75/5 Refinishing Steering Damper Knob</a>

<h2>Headlight Shell Restoration</h2>
<a title="97,553 miles, 2 owners by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8316724088/"><img alt="97,553 miles, 2 owners" src="http://farm9.staticflickr.com/8071/8316724088_e7a2916391.jpg" width="500" height="375" /></a>
Headlight Shell After 40 Years, 97,553 miles

<a title="Headlight Shell Underside Detail by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8391353972/"><img alt="Headlight Shell Underside Detail" src="http://farm9.staticflickr.com/8190/8391353972_5c62555931.jpg" width="500" height="375" /></a>
Headlight Shell Underside Grunge

<a title="Headlight Paint - Like New by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8567011090/"><img alt="Headlight Paint - Like New" src="http://farm9.staticflickr.com/8103/8567011090_a54b8d7b22.jpg" width="500" height="375" /></a>
Headlight Paint Repair - Like New Again

<a title="Refinished Switches by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8566343461/"><img alt="Refinished Switches" src="http://farm9.staticflickr.com/8390/8566343461_f1de9be2e8.jpg" width="500" height="375" /></a>
Restored Switch Assemblies

<h2>Header Restoration</h2>
<a title="Header with 40 Years of Bluing by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8567011666/"><img alt="Header with 40 Years of Bluing" src="http://farm9.staticflickr.com/8390/8567011666_c46cdaf183.jpg" width="500" height="375" /></a>
Header with 40 Years of Bluing

<a title="Header with 40 Years of Bluing by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8567011370/"><img alt="Header with 40 Years of Bluing" src="http://farm9.staticflickr.com/8085/8567011370_c4d845c156.jpg" width="500" height="375" /></a>
Header with 40 Years of Bluing

<a title="Header with 40 Years of Bluing by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8565915205/"><img alt="Header with 40 Years of Bluing" src="http://farm9.staticflickr.com/8248/8565915205_763ccf81ac.jpg" width="500" height="375" /></a>
Header with 40 Years of Bluing

<a title="Header Cleaned & Polished by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8565915457/"><img alt="Header Cleaned & Polished" src="http://farm9.staticflickr.com/8094/8565915457_bec4ed4a25.jpg" width="500" height="375" /></a>
Restored Header Clean & Polished

<a title="Header Cleaned & Polished by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8567011546/"><img alt="Header Cleaned & Polished" src="http://farm9.staticflickr.com/8107/8567011546_af0759850b.jpg" width="500" height="375" /></a>
Restored Header Clean & Polished

<h2>Steering Damper Restoration</h2>
<a title="Steering Head Grunge & Damper by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8315667821/"><img alt="Steering Head Grunge & Damper" src="http://farm9.staticflickr.com/8222/8315667821_2ce96640d1.jpg" width="500" height="375" /></a>
Steering Damper Dings and Steering Head Grunge

<a title="Steering Head Polish $4 by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8565915843/"><img alt="Steering Head Polish $4" src="http://farm9.staticflickr.com/8386/8565915843_c69c942eae.jpg" width="500" height="375" /></a>
Steering Head After Polish #4
 
Brook, I haven't heard back from the guy in Lou,KY that had his bike striped but I'm going to the same guy after I paint my fenders-tank stripes I'm still deciding as I change my mind back/forth on those. The blinker switches-did you spray clear on the levers?
 
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Brook, I haven't heard back from the guy in Lou,KY that had his bike striped but I'm going to the same guy after I paint my fenders-tank stripes I'm still deciding as I change my mind back/forth on those. The blinker switches-did you spray clear on the levers?

Hi Kentuckid,

The clutch and brake levers are just polished, no clear coat. I hadn't thought about putting clear coat on them. The switch housings also have no clear coat. That's the level of gloss in the Dupli-color Universal Black touch up paint.

Keep me posted on the stripes.

PS: What did you teach when you taught?

Best.
Brook.
 
1973 R75/5 Renewing Cylinders, Valve Covers & Heads

I wrote up a web page on this and here is the link.
<ul>
<li><a style="font-size: medium;" href="http://brook.reams.me/about/bmw-motorcyle-rebuilds/1973-bmw-r755-rebuild-project/11-bmw-r755-cylinder-cleanup-and-head-rebuild/">11 BMW R75/5 Cylinder Cleanup and Head Rebuild</a></li>
</ul>
I sent the cylinders, valve covers and exhaust nuts for bead blasting to a local shop in Arvada, CO, <a href="http://www.roadiesperformance.com/">Roadies Performance</a>, that does bead blasting for me, and send the heads for a complete rebuild to Randy Long.

Here is a sample of the pictures I took and there are more in the web page.

<img alt="Bead Blasted Cylinders, Valve Covers and Exahaust Nuts" src="http://farm9.staticflickr.com/8227/8584628352_75b3096871.jpg" width="500" height="375" /></a>
Bead Blasted Cylinders, Valve Covers and Exhaust Nuts


<img alt="Rebuilt Heads" src="http://farm9.staticflickr.com/8365/8579458938_703857c8fd.jpg" width="500" height="375" /></a>
Rebuilt Heads by Randy Long

<img alt="Airbox Covers, Before Polish & After" src="http://farm9.staticflickr.com/8528/8583527859_5990937f05.jpg" width="500" height="375" /></a>
Air Box Covers, Before & After Clean Up
 
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Aha!
Somehow I missed the link before.
Nice detailed post.
Those things look fantastic! Let us know how long it lasts.

Cool project, BTW. Great documentation. Nice to see that bike getting all that love.
 
1973 R75/5 Rebuild, Repairing Stripped Threads in Handlebar Control Assembly

As I was putting the handlebar assemblies back together, I discovered a stripped thread in the casting that holds the pinch bolt. I did a HeliCoil repair, which is the first time I have had to repair threads in an expensive part.

I wrote up a web page on how to repair stripped threads in the assembly.
<ul>
<li><a href="http://brook.reams.me/about/bmw-motorcyle-rebuilds/1973-bmw-r755-rebuild-project/32-bmw-r755-handlebar-assembly-stripped-thread-repair/">32 BMW R75/5 Handlebar Assembly Stripped Thread Repair</a></li>
</ul>
Here are a couple the pictures I took along the way.

<img alt="Striped Threads & Compression Bolt" src="http://farm9.staticflickr.com/8524/8584649090_e92a300499.jpg" width="500" height="375" /></a>
Stripped Thread & Compression Bolt

<img alt="Threading Heilcoil Tap" src="http://farm9.staticflickr.com/8239/8584648814_971a75fbbc.jpg" width="500" height="375" /></a>
Running Tap in from Back Side of Assembly

<img alt="Threading Insert into Tapped Hole" src="http://farm9.staticflickr.com/8518/8584648550_c90fcca828.jpg" width="500" height="375" /></a>
Threading the Insert into Tapped Hole From Backside of Assembly

Here are the finished left and right hand handlebar assemblies with new powder coating and polished levers. *I think they are going to look very nice on the new handlebar.

<img alt="Assembled Left Side Clutch Assembly" src="http://farm9.staticflickr.com/8511/8583547875_7fa515518b.jpg" width="500" height="375" /></a>
Assembled Left Side Clutch Assembly

<img alt="Assembled Right Side Throttle Assembly" src="http://farm9.staticflickr.com/8105/8584648358_6a590c0781.jpg" width="500" height="375" /></a>
Assembled Right Side Throttle Assembly
 
1973 R75/5 Refinishing Transmission & Rear Drive

I posted a short blog about refinishing the transmission, part of the effort this weekend.


This is not about a rebuild, but a refinish. The blog has links to both the transmission and rear drive web pages with all the refinishing pictures and narrative. I had "fun" getting the kick start and shift lever tapered bolts out, but I polished the bolts and holes and everything went together smoothly. Here are a couple of the pictures you will find.

<a href="http://www.flickr.com/photos/brook-reams/8629171955/" title="Rear Grunge by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8533/8629171955_af841e138e.jpg" width="500" height="375" alt="Rear Grunge"></a>
Rear Transmission Grunge

<a href="http://www.flickr.com/photos/brook-reams/8630280086/" title="Top Side Grunge by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8526/8630280086_1b91f38543.jpg" width="500" height="375" alt="Top Side Grunge"></a>
Top Transmission Grunge

<a href="http://www.flickr.com/photos/brook-reams/8629171817/" title="Front Gunge by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8395/8629171817_967ca2b471.jpg" width="500" height="375" alt="Front Gunge"></a>
Front Transmission Grunge

<a href="http://www.flickr.com/photos/brook-reams/8629171517/" title="Polished Parts by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8108/8629171517_9f32231374.jpg" width="500" height="375" alt="Polished Parts"></a>
Polished Pieces

<a href="http://www.flickr.com/photos/brook-reams/8629171385/" title="Refinished Top by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8116/8629171385_0f52fe3982.jpg" width="500" height="375" alt="Refinished Top"></a>
Refinished Transmission Top

<a href="http://www.flickr.com/photos/brook-reams/8629171253/" title="Refinished Left Side by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8121/8629171253_3e0e85000d.jpg" width="500" height="375" alt="Refinished Left Side"></a>
Refinished Transmission Left Side

<a href="http://www.flickr.com/photos/brook-reams/8617484133/" title="Rear Drive Before Cleaning by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8533/8617484133_dba02883e5.jpg" width="500" height="375" alt="Rear Drive Before Cleaning"></a>
Rear Drive Before Cleaning

<a href="http://www.flickr.com/photos/brook-reams/8618592968/" title="Brake Shoe Orientation by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8538/8618592968_caf4837e75.jpg" width="500" height="375" alt="Brake Shoe Orientation"></a>
Inside Rear Drive Showing Brake Shoe Orientation

<a href="http://www.flickr.com/photos/brook-reams/8623777580/" title="Refinished Rear Drive by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8538/8623777580_ac60de36e0.jpg" width="500" height="375" alt="Refinished Rear Drive"></a>
Inside Rear Drive Refinished with Polished Parts

<a href="http://www.flickr.com/photos/brook-reams/8623777562/" title="Refinished Rear Drive by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8124/8623777562_701f3d4331.jpg" width="500" height="375" alt="Refinished Rear Drive"></a>
Outside Rear Drive Refinished
 
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1973 R75/5 Refinishing Boge Rear Shocks

I removed and inspected the Boge rear shocks to see if they could be used. I really wanted to retain the stock chrome shock covers if possible. I decided they are still serviceable, so I refinished them including powder coating the springs and removing the deep scratches in the shock covers. I wrote up a web page on this and here is the direct link to it.


Below are a couple of the pictures included in the web page write up.

<img alt="Hose Clamp Spring Compressor" src="http://farm9.staticflickr.com/8527/8593128750_bf2b7d97a7.jpg" width="375" height="500" /></a>
Hose Clamp Spring Compressor

<img alt="Shackle and Spring Removed" src="http://farm9.staticflickr.com/8516/8593128730_e1de8da183.jpg" width="375" height="500" /></a>
Shackle and Spring Removed

<img alt="Polished & Powder Coated Parts" src="http://farm9.staticflickr.com/8104/8642083060_f2b9552dee.jpg" width="500" height="375" /></a>
Polished & Powder Coated Parts

<img alt="Refinished Shock" src="http://farm9.staticflickr.com/8257/8640981525_b4a54ac6c6.jpg" width="500" height="375" /></a>
Refinished Shock
 
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1973 R75/5 Swing Arm, Bearing Replacement & Powder Coat

I posted another chapter on this project about replacing the swing arm bearings and powder coating the swing arm. This blog post has a link to the web page I wrote about this.


I hope this is helpful to folks. Here are few sample pictures from the web page to wet your appetite.

<img alt="Cycle Works Swing Arm Bearing Puller Kit" src="http://farm9.staticflickr.com/8263/8616664143_8ffa4f09a8.jpg" width="500" height="375" /></a>
Cycle Works Swing Arm Bearing Puller Kit

<img alt="Removing the Spacer" src="http://farm9.staticflickr.com/8243/8616664057_390b34107b.jpg" width="500" height="375" /></a>
Removing the Spacer

<img alt="Puller Positioned to Remove the Dust Seal" src="http://farm9.staticflickr.com/8530/8617769858_e0c5158ab8.jpg" width="500" height="375" /></a>
Puller Positioned to Remove the Dust Seal

<img alt="Progresso Soup Can "Sock" Over the Universal Joint" src="http://farm9.staticflickr.com/8540/8617769718_685712358f.jpg" width="500" height="375" /></a>
Progresso Soup Can "Sock" Over the Universal Joint

<img alt="Powder Coated Swing Arm" src="http://farm9.staticflickr.com/8249/8642325527_8b639a3e8e.jpg" width="500" height="375" /></a>
Powder Coated Swing Arm

<img alt="Swing Arm Bearing Parts-Top to Bottom, Inside to Outside" src="http://farm9.staticflickr.com/8244/8647587570_3d77c2ab8c.jpg" width="375" height="500" /></a>
Swing Arm Bearing Parts-Top to Bottom, Inside to Outside, Left is Drive Shaft Side, Right is Shock Side

<img alt="Shock Side, Bearing Race and Grease Cap Installed" src="http://farm9.staticflickr.com/8241/8646490951_180f1f0128.jpg" width="500" height="375" /></a>
Shock Side Showing Bearing Race and Grease Cover Installed

<img alt="Dust Seal with Sleeve Installed" src="http://farm9.staticflickr.com/8541/8647587104_5b5686c6b4.jpg" width="500" height="375" /></a>
Dust Seal with Sleeve Installed
 
1973 R75/5 Replacing Steering Head Bearings

Folks,

I posted a report on this part of the project:
http://brook.reams.me/about/bmw-mot...t/31-bmw-r755-replace-steering-head-bearings/

that contains a link to a web page I wrote up about what I did:
http://brook.reams.me/about/bmw-mot...t/31-bmw-r755-replace-steering-head-bearings/

This is a milestone on the project as I am now reassembling parts in the frame instead of disassembling them. :clap

I hope this material is helpful to others. Here are a couple of the many pictures I put in the web page.

<img alt="Fork tubes removed" src="http://farm9.staticflickr.com/8362/8404891455_226aba37c6.jpg" width="500" height="375" /></a>
Steering Head After Forks Removed

<img alt="Steering Stem" src="http://farm9.staticflickr.com/8517/8405984718_2a7b1a464e.jpg" width="500" height="375" /></a>
Steering Stem Showing Top Bearing

<img alt="BMW Steering Head Race puller" src="http://farm9.staticflickr.com/8514/8443589216_e2a7d96921.jpg" width="375" height="500" /></a>
BMW Steering Head Race puller

<img alt="Old Race-Vertical Bands Indicate Brinelling" src="http://farm9.staticflickr.com/8101/8649381473_6af8f2bd51.jpg" width="500" height="375" /></a>
Top Race with Vertical Bands Indicating Brinelling

<img alt="Bottom Bearing Slipped On and Seated on the Steering Stem" src="http://farm9.staticflickr.com/8259/8650482098_9f27644478.jpg" width="500" height="375" /></a>
Bottom Bearing Slipped On and Seated on the Steering Stem

<img alt="Top & Bottom Bearings Packed with Grease" src="http://farm9.staticflickr.com/8403/8649381145_210424fc54.jpg" width="500" height="375" /></a>
Top & Bottom Bearings Packed with Grease

<img alt="New Chrome Top Dust Cap Really Shines" src="http://farm9.staticflickr.com/8264/8649380773_155e24d740.jpg" width="500" height="375" /></a>
New Chrome Top Dust Cap Really Shines
 
1973 R75/5 Rebuild, Measuring Cylinders & Pistons, Installing New Rings

I documented this work here.
1973 BMW R75/5 Rebuild: Measuring Cylinders, Pistons and Installing New Rings

It contains a link to the web page I wrote up with the details of what I did.

I hope this is useful to others who are considering doing this kind of work.

Here is a sample of the pictures I took along the way.

<a href="http://www.flickr.com/photos/brook-reams/8667618960/" title="Zeroing Micrometer with 3 inch Reference by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8253/8667618960_0e6121bde7.jpg" width="500" height="375" alt="Zeroing Micrometer with 3 inch Reference"></a>
Zeroing Micrometer

<a href="http://www.flickr.com/photos/brook-reams/8667618970/" title="Bore Guage by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8256/8667618970_e599b1baf4.jpg" width="500" height="375" alt="Bore Guage"></a>
Bore Gauge with Dial Indicator

<a href="http://www.flickr.com/photos/brook-reams/8667618562/" title="Setting Bore Gauge by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8260/8667618562_2fab96cfcf.jpg" width="500" height="375" alt="Setting Bore Gauge"></a>
Setting Bore Gauge to Known Length

<a href="http://www.flickr.com/photos/brook-reams/8667618424/" title="Bore Diameter by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8264/8667618424_23fd92024b.jpg" width="375" height="500" alt="Bore Diameter"></a>
Measuring Bore Diameter

<a href="http://www.flickr.com/photos/brook-reams/8701552869/" title="Measuring Piston Diameter on Thrust Side of Skirt by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8419/8701552869_70eabd12a8.jpg" width="500" height="375" alt="Measuring Piston Diameter on Thrust Side of Skirt"></a>
Measuring Piston Diameter on Wide Side

<a href="http://www.flickr.com/photos/brook-reams/8698623169/" title="Inserting Hone in Cylinder by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8114/8698623169_fcfb490904.jpg" width="500" height="375" alt="Inserting Hone in Cylinder"></a>
Inserting Hone in the Cylinder

<a href="http://www.flickr.com/photos/brook-reams/8699747464/" title="New Rings by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8404/8699747464_17611f533d.jpg" width="500" height="375" alt="New Rings"></a>
New Rings, One Over Size

<a href="http://www.flickr.com/photos/brook-reams/8699747340/" title="Positioning Ring for Grinding Gap by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8400/8699747340_d801a64c55.jpg" width="500" height="375" alt="Positioning Ring for Grinding Gap"></a>
Positioning Ring In Ring Grinder

<a href="http://www.flickr.com/photos/brook-reams/8698623039/" title="Measuring Ring End Gap by ScooterScum_52, on Flickr"><img src="http://farm9.staticflickr.com/8418/8698623039_ba3e9010eb.jpg" width="500" height="375" alt="Measuring Ring End Gap"></a>
Measuring End Gap - Perfect
 
R75/5 Rebuild: Clutch Removal and Inspection

It has been awhile since I posted on this project. My wife and I spent six weeks in Europe celebrating our 35th anniversary by participating in some "applied motorcycling" taking two motorcycle tours and doing some sight seeing.

Here is a link to a recent progress report on the project:
http://brook.reams.me/2013/08/08/1973-r755-rebuild-progress-report-2/

This is a link to today's posting about removal and inspection of the clutch;
http://brook.reams.me/2013/08/13/1973-r755-rebuild-clutch-removal-and-inspection/

And for those interested in riding in eastern Europe in what was once Yugoslavia as well as Bulgaria and Albania, here is my trip report. I'll post one on the tour of the Pyrenees pretty soon.
http://brook.reams.me/2013/07/12/a-motorcycle-tour-of-eastern-europe-combat-touring-in-the-balkans/

And, a tip of the hat to Tom Cutter and Bob Fleischer (aka, Snowbum) for sharing their considerable knowledge. It is much appreciated. And of course any mistakes made in my work are mine alone and do not reflect on these guys. ;-)

Here are some of the pictures from my write up.

<a title="Bar Prevents Rotation When Removing Clutch Bolts by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8717831090/"><img alt="Bar Preventing Rotation When Removing Clutch Bolts" src="http://farm8.staticflickr.com/7429/8717831090_c1105623cc.jpg" width="500" height="375" />
Bar Preventing Rotation When Removing Clutch Bolts

<a title="Backing Off Clutch Pressure by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8716711469/"><img alt="Backing Off Clutch Pressure 1/2 Turn Per Bolt at a Time" src="http://farm8.staticflickr.com/7418/8716711469_d74b76ff13.jpg" width="500" height="375" />
Backing Off Clutch Pressure 1/2 Turn Per Bolt at a Time

<a title="Parts Order by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8716711379/"><img alt="Clutch Parts Order: Bottom Clutch Pressure Ring, Top Clutch Diaphragm Spring" src="http://farm8.staticflickr.com/7356/8716711379_3bf397704d.jpg" width="500" height="375" />
Clutch Parts Order: Bottom Clutch Pressure Ring, Top Clutch Diaphragm Spring

<a title="Diaphram Spring Fingers by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8716711075/"><img alt="Diaphragm Spring Finger-Wear on Edges" src="http://farm8.staticflickr.com/7338/8716711075_28f05bc5d8.jpg" width="500" height="375" />
Diaphragm Spring Finger-Wear on Edges

<a title="Pressure Plate Facing Engine by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8716711351/"><img alt="Clutch Pressure Plate Facing Engine Showing Grooves from Diaphragm Spring" src="http://farm8.staticflickr.com/7359/8716711351_c35573bd93.jpg" width="500" height="375" />
Clutch Pressure Plate Facing Engine Showing Grooves from Diaphragm Spring
 
I got in here late

But, thank you Brook for all the nice pics and your journal. You do nice work and contributions like this help us all.:thumb

DW
 
But, thank you Brook for all the nice pics and your journal. You do nice work and contributions like this help us all.:thumb

DW

Thanks for the kind words DW. For some reason, documenting this type of work is enjoyable to me, and of course doing the work is engaging and challenging, so I have a good time.

PS: I like that RS in your photo. I lust for one to rebuild and it is on my list for "next projects".
 
R75/5 Rebuild: Remove/Replace Flywheel, Replace Oil Pump Cover & Cover O-ring

I posted a new page on this project about removing the flywheel, replacing the rear main seal, oil pump cover and cover o-ring and installing the flywheel. This also covers a repair to a leak I found in one of the crankshaft flywheel bolt holes.

http://brook.reams.me/2013/08/14/19...ace-rear-main-seal-oil-pump-cover-and-o-ring/

The work I did was guided by a lot of advice and web content shared by others who have gone before me. I?d like to acknowledge folks Tom Cutter who runs Rubber Chicken Racing Garage and Bob (Snowbum) Fleischer who has a great technical library on all things BMW motorcycles, answered questions I posted on the Micapeak forum and in personal Email and phone conversations. I also used web materials posted on Duane Ausherman?s site.

Any errors in procedure are entirely my own and in no way reflect on the knowledge of the people above.

Here are a couple pictures from the many posted in the write-up.

<a title="10mm Long Bolt in Alternator to Block Crackshaft by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8717831146/"><img alt="10mm Long Bolt in Alternator to Block Crackshaft" src="http://farm8.staticflickr.com/7288/8717831146_c67a8a2f57.jpg" width="500" height="375" />
10mm Long Bolt in Alternator to Block Crackshaft

<a title="Flywheel Bolts out And Oil Leaking by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8717830954/"><img alt="Flywheel Bolts out And Oil Leaking" src="http://farm8.staticflickr.com/7281/8717830954_0425c77a50.jpg" width="500" height="375" /><
Flywheel Bolts Out And Oil Leaking From Crankshaft Hole

<a title="Removing Oil Pump Cover with Impact Driver by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8717830834/"><img alt="Removing Oil Pump Cover with Impact Driver" src="http://farm8.staticflickr.com/7394/8717830834_0ccd1a5faf.jpg" width="500" height="375" />
Removing Oil Pump Cover with Impact Driver

<a title="Tightening Bolt to Pull Oil Seal by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/9495946745/"><img alt="Tightening Bolt to Pull Rear Main Seal" src="http://farm3.staticflickr.com/2813/9495946745_1e49dc7f9d.jpg" width="500" height="375" />
Tightening Bolt to Pull Rear Main Seal

<a title="Heated to 220 F by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/9487898499/"><img alt="Heated to 220 F" src="http://farm8.staticflickr.com/7392/9487898499_3fb6537cae.jpg" width="500" height="375" />
Heating Flywheel Bolt Circle to 220 F Prior To Installation
 
8716711351_c35573bd93.jpg

Clutch Pressure Plate Facing Engine Showing Grooves from Diaphragm Spring

Geez, that's wild! That must have been one gritty feeling clutch.

8717830834_0ccd1a5faf.jpg

Removing Oil Pump Cover with Impact Driver

How in the heck can you get a swing in that small space? It's impossible to use a handheld impact on my /6s.
 
Geez, that's wild! That must have been one gritty feeling clutch.



How in the heck can you get a swing in that small space? It's impossible to use a handheld impact on my /6s.

Hi CrazyDrummerDude,

Thanks for visiting this thread.

[gritty clutch] The bike had not been ridden for 6 years before I started rebuilding it. That said, it is my wife's bike so I haven't any sense of how the clutch was working, but it was working when I put it up on blocks 6 years ago. Based on the measurements, it didn't have much life left. :)

[impact driver comment] Indeed, this is not as easy if the engine is in the frame. But mine's out of the frame. However, with the transmission, rear frame and swing arm removed, you have room to use the mallet. It doesn't take a big swing to get the torque onto the screw head.
 
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