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1973 R75/5 Rebuild Project Journal

Your work is a real pleasure to read/ view.
Perhaps a trick of the camera lens, but is your rear wheel axle shaft bent slightly?
 
Your work is a real pleasure to read/ view.
Perhaps a trick of the camera lens, but is your rear wheel axle shaft bent slightly?

Hi RT100RTurbo,

Thanks for the kind words.

Indeed, there is a bit of "fish eye" distortion at the top of that picture. The rear axle is straight.

Best.
Brook.
 
Brook, you been wrenching on Airheads quite a while? I dearly wish I could even attempt what you are doing.
Beautiful work there. Wow. You ever get to East Coast of Florida? Ha. :beer
 
Brook, you been wrenching on Airheads quite a while? I dearly wish I could even attempt what you are doing.
Beautiful work there. Wow. You ever get to East Coast of Florida? Ha. :beer

Hi captianMako21,

Thank you for the kind words.

I've owned airheads since 1975 and picked up a bit here and there, but most of it was routine service work. My edumacation in rebuilding really started in 2010 as a result of a desire to reconnect doing with thinking. I felt I had lost that balance over the years. I had just turned 100,000 miles on my first BMW a 1975 R75/6, the "Grey Ghost", and I thought rebuilding that bike would be a good way to get the balance back. Well, it was. And now, rebuild #2 is making progress :)

"BEER" oh, well, that's a very strong inducement to ride to Florida as another hobby of mine is home brewing (yeah, another attempt to reconnect doing with thinking with built in rewards) :)

Thanks for reading along as this project progress.

Best.
Brook.
 
My edumacation in rebuilding really started in 2010 as a result of a desire to reconnect doing with thinking. I felt I had lost that balance over the years.

This is the reason I built a maintenance intensive bike for my daughter (now three), I wanted something she could learn to use a wrench with and think mechanically with, then once she fully knows her way around the bike I'll turn the title over. Let's face it, the new generations (mine included) simply don't get an education in these kinds of things anymore (like Matthew Crawford complaining about modern education looking down on shop class and trades) and in another 10 years modern cars are going to be impossible to work on like our airheads. At least my modern VWs still let me wrench a little on them without a computer, and more importantly, have dipsticks, unlike my brother in law's Audi!

The level of finish on your bike has me thinking about my next build. With my R90, I customized it to my liking (paint, tuning, suspension, etc.), but other than giving a good clean and bit of polish, pretty much left the frame and drive train original, I think going full resto would just drive me nuts as I use the bike on a regular basis all year round. On the next bike I went crazier, but definitely not at this level of finish. Now that my hands are idle once again, I'm thinking of heading in your direction. With the "Grey Ghost," do you find that it's difficult to keep that kind of cleanliness with normal use, particularly in the cylinder fins? I feel like I'd need to use a toothbrush on it after every single ride.

Also, where'd you buy that neat seal puller?
 
...With the "Grey Ghost," do you find that it's difficult to keep that kind of cleanliness with normal use, particularly in the cylinder fins? I feel like I'd need to use a toothbrush on it after every single ride.

Also, where'd you buy that neat seal puller?

Hi Type181R90,

I included the info on the Lisle shaft seal puller here:
11 BMW R75/5 Replace Cam Shaft Seal


And show using it here on the front crankshaft seal:
11 BMW R75/5 Replace Front Crankshaft Seal

You raise an interesting point about how to treat a restored bike I spent a year rebuilding and spent $$ on, and which I planned to continue riding when I got done. I came to the conclusion that the rebuild was a journey to be enjoyed for the accomplishment, challenges and learning I received along the trip. Riding is riding, and a series of journeys to be enjoyed for the experience of riding a classic motorcycle. Dirt, stones, nicks and grime come with riding. So over time, I will have an opportunity to "refresh" the Grey Ghost again. I expect to have as much fun then as I did on the original rebuild project, and will learn more in the bargain.

Thanks for reading the journal about this project.

Best.
Brook.
 
1973 R75/5 Rebuild, Install Rear Sub-Frame, Shocks, Key Lock & Seat Latch

Folks,

I made great progress on the back end. I wrote up this work here:

I'm reading up on the front fork installation and elimination of "Stiction" in the Randy Glass and Bob Fleischer documentation. That's where I'm headed next; right after I finish painting and hanging the new downstairs doors. I have to pay the wifely dues every now and then if I want to have "play time" in the shop :)

Here's a couple of pictures from the write-up.

<a title="Rear Frame by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10355400504/"><img alt="Rear Frame" src="http://farm6.staticflickr.com/5548/10355400504_6dea6f7d0f_z.jpg" width="640" height="480" /></a>
Rear Sub-Frame, Upside Down

<a title="Securing Shocks by Lower Shackle by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10355403896/"><img alt="Securing Shocks by Lower Shackle" src="http://farm8.staticflickr.com/7347/10355403896_8e957c9607_z.jpg" width="640" height="480" /></a>
Securing Shocks by Lower Shackle

<a title="Seat Latch and Lock Hardware by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10355590653/"><img alt="Seat Latch and Lock Hardware" src="http://farm4.staticflickr.com/3678/10355590653_f44d0cac36_z.jpg" width="640" height="480" /></a>
Key Lock and Seat Latch Hardware

<a title="Lock Retaining Ring on Lock by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10355398704/"><img alt="Lock Retaining Ring on Lock Barrel" src="http://farm6.staticflickr.com/5482/10355398704_59945d0a1f_z.jpg" width="640" height="480" /></a>
Lock Retaining Ring on Lock Barrel

<a title="Lock Mechanisum by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10355590043/"><img alt="Seat Latch Goes Around Key Lock" src="http://farm8.staticflickr.com/7364/10355590043_90206d2c8f_z.jpg" width="640" height="480" /></a>
Seat Latch Goes Around Key Lock

<a title="Rear Shocks Installed by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10355399595/"><img alt="Rear Shocks Installed" src="http://farm8.staticflickr.com/7387/10355399595_2742037ab2_z.jpg" width="640" height="480" /></a>
Final Product

<a title="Lock & Grab Handle by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10355402116/"><img alt="Lock & Grab Handle" src="http://farm6.staticflickr.com/5481/10355402116_9d72e36057_z.jpg" width="640" height="480" /></a>
Key Lock and Grab Handle Installed
 
1973 R75/5 Rebuild, Refinishing Techniques

I've had several questions and Email about how I refinish the rough aluminum casting on the engine, transmission and rear drive and also some questions on how I got the carburetors to look shiny and new again.

NOTE: Refinishing is not rebuilding. Refinishing is restoring the surface of parts to "like new" condition. You are removing crud, stains, grime, dirt, grease, bugs, corrosion, tar, mud and old gasket sealer that have frequently been baked on for 10, 20, 30 or more years. It takes PATIENCE. It is applied Zen :)

So, I put this together:


Some Before/After pictures from this are below.

<a title="Fork slider details by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8404891633/"><img alt="Fork slider details" src="http://farm9.staticflickr.com/8095/8404891633_9fb1c0b85a_z.jpg" width="640" height="480" /></a>
Lower Fork Sliders

<a title="After Rebuild & Polishing by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8427858701/"><img alt="After Rebuild & Polishing" src="http://farm9.staticflickr.com/8093/8427858701_0312131164_z.jpg" width="640" height="480" /></a>
Refinished Front Forks Lowers

<a title="Rear Drive by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8443616388/"><img alt="Rear Drive" src="http://farm9.staticflickr.com/8473/8443616388_8c129ca7e2_z.jpg" width="640" height="480" /></a>
Rear Drive with Baked on Stain from Gear Lube

<a title="Refinished Rear Drive by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8623777562/"><img alt="Refinished Rear Drive" src="http://farm9.staticflickr.com/8124/8623777562_701f3d4331_z.jpg" width="640" height="480" /></a>
Refinished Rear Drive

<a title="Transmission crud by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8451536565/"><img alt="Transmission Crud" src="http://farm9.staticflickr.com/8107/8451536565_aee901d04e_z.jpg" width="640" height="480" /></a>
Transmission

<a title="Refinished Rear by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8629171117/"><img alt="Refinished Rear" src="http://farm9.staticflickr.com/8255/8629171117_731db9c04a_z.jpg" width="640" height="480" /></a>
Refinished Transmission

<a title="Carb & shaft drive gunge by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8315669683/"><img alt="Carb & shaft drive gunge" src="http://farm9.staticflickr.com/8352/8315669683_6fc86a16ba_z.jpg" width="640" height="480" /></a>
Air Box and Engine

<a title="Polished Engine by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/9866823366/"><img alt="Polished Engine" src="http://farm8.staticflickr.com/7318/9866823366_04456e5a0c_z.jpg" width="640" height="480" /></a>
Refinished Engine Case and Timing Cover

<a title="Before Soak, After Soak by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8332172648/"><img alt="Before Soak, After Soak" src="http://farm9.staticflickr.com/8081/8332172648_ae6e52d408_z.jpg" width="640" height="480" /></a>
Before Soak, After Soak

<a title="Cleaned and Polished, Outside View by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/8331121263/"><img alt="Cleaned and Polished, Outside View" src="http://farm9.staticflickr.com/8356/8331121263_1d7c75bdb4_z.jpg" width="640" height="480" /></a>
Cleaned and Polished, Outside View
 
Last edited:
1973 R75/5 Rebuild, Install and Align Front Forks

Folks,

Another project milestone complete. This took some time and patience to get the fork tubes aligned. I also added a modern BMW emblem to the center of the steering damper knob.

You can read about what I did here:
  • 31 BMW R75/5 Install and Align Front Forks

I'll work on installing the front brakes and wheel next.

Here are a couple pictures from the write-up.

<a title="Steering Head after New Bearings Installed by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10543604344/"><img alt="Steering Head after New Bearings Installed" src="http://farm6.staticflickr.com/5488/10543604344_2cb88e89e1_z.jpg" width="640" height="480" /></a>
Steering Head with Steering Stem After New Bearings Installed

<a title="Fork Sliders, Top is Right Side, Bottom is Left Side with Axle Clamp Allen Head Screw by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10543604164/"><img alt="Fork Sliders, Top is Right Side, Bottom is Left Side with Axle Clamp Allen Head Screw" src="http://farm6.staticflickr.com/5486/10543604164_43d2e5f20c_z.jpg" width="640" height="480" /></a>
Fork Sliders, Top is Right Side, Bottom is Left Side with Axle Clamp Allen Head Screw

<a title="Forks Mounted and Lower.s Removed by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10543565045/"><img alt="Forks Mounted and Lower Sliders Removed" src="http://farm8.staticflickr.com/7420/10543565045_208849702c_z.jpg" width="480" height="640" /></a> Forks Mounted and Lower Sliders Removed

<a title="Postoning Glass on Fork Tubes by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10567795743/"><img alt="Positioning Glass on Fork Tubes" src="http://farm4.staticflickr.com/3772/10567795743_759b2dc6bc_z.jpg" width="640" height="480" /></a>
Positioning Glass on Fork Tubes

<a title="Fork Alignment in Y-Direction by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10543602514/"><img alt="Fork Alignment in X-Direction" src="http://farm6.staticflickr.com/5478/10543602514_01e7414845_z.jpg" width="640" height="480" /></a>
Aligning Forks in Y-Direction with 2 x 4 Between Fork Tubes

<a title="X-Plane Measurement at Bottom of Tube by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10560939735/"><img alt="X-Plane Measurement at Bottom of Tube" src="http://farm6.staticflickr.com/5514/10560939735_64557732bb_z.jpg" width="640" height="480" /></a>
X-Plane Measurement at Bottom of Fork Tubes

<a title="Clamping Forks Below Yolk to Adjust X-Plane Alignment by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10561560113/"><img alt="Clamping Forks Below Yolk to Adjust X-Plane Alignment" src="http://farm6.staticflickr.com/5545/10561560113_e813f51c01_z.jpg" width="640" height="480" /></a>
Clamping Forks Below Yoke to Adjust X-Plane Alignment

<a title="Lowers with Fork Brace Installed by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10695285496/"><img alt="Lowers with Fork Brace Installed" src="http://farm4.staticflickr.com/3694/10695285496_ebc57c7601_z.jpg" width="480" height="640" /></a>
Lowers with Fork Brace Installed

<a title="Install Damper Friction Bracket by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10801257635/"><img alt="Install Damper Friction Bracket" src="http://farm8.staticflickr.com/7389/10801257635_73bc64cde8_z.jpg" width="480" height="640" /></a>
Install Damper Friction Bracket

<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_z.jpg" width="640" height="480" /></a>
Original Steering Head Grunge & Damper Scratches

<a title="Finished Upper Fork Brace with Damper and Handlebar Mounts by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10801506693/"><img alt="Finished Upper Fork Brace with Damper and Handlebar Mounts" src="http://farm6.staticflickr.com/5543/10801506693_3ff552902d_z.jpg" width="640" height="480" /></a>
Finished Upper Fork Brace with Damper and Handlebar Mounts


<a title="Polished Damper Knob, Emblem and Polished Upper Brace by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10801506383/"><img alt="Polished Damper Knob, Emblem and Polished Upper Brace" src="http://farm8.staticflickr.com/7374/10801506383_39096eb72b_z.jpg" width="640" height="480" /></a>
Polished Damper Knob, Emblem and Polished Upper Brace


Best.
Brook Reams
 
1973 R75/5 Rebuild, Install Front Brakes

Folks,

More progress as I now have the new front brakes, brake cable & handlebars installed. You can read about how I did this work here.
  • 34 BMW R75/5 Install Front Brakes
Thanks to Bob Fleischer, again, for tips and tricks and to Duane Ausherman and Scott Lydiard for their publications.

I'm working on installing all the electrics next.

Here are a couple pictures from the write-up on this work.

<a title="Front Brake Housing (Front to the Right) by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10813082724/"><img alt="Front Brake Carrier (Front to the Right)" src="http://farm6.staticflickr.com/5516/10813082724_dc07db07bc_z.jpg" width="640" height="480" /></a>
Front Brake Carrier (Front to the Right)

<a title="Front Brake Assembly by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10812948095/"><img alt="Front Brake Assembly" src="http://farm8.staticflickr.com/7369/10812948095_e996513907_z.jpg" width="480" height="640" /></a>
Front Brake Assembly

<a title="Front Pivot Shaft and Adjustment Cam by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10813082114/"><img alt="Rear Brake Cam Shaft Lever and Adjustment Cam" src="http://farm6.staticflickr.com/5516/10813082114_cc3536911f_z.jpg" width="640" height="480" /></a>
Front Brake Arm Cam with Lever and Adjustment Cam

<a title="Front Spring &Top Shoe Installed by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10813081444/"><img alt="Front Spring Installed and Shoes on Pivot Pins" src="http://farm6.staticflickr.com/5503/10813081444_28b5a8e69b_z.jpg" width="640" height="480" /></a>
Front Spring Installed and Shoes on Pivot Pins

<a title="Scott Lydiard's Brake Lever Alignment Template by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10838934476/"><img alt="Scott Lydiard's Brake Lever Alignment Template" src="http://farm4.staticflickr.com/3695/10838934476_d8328fcf6b_z.jpg" width="640" height="480" /></a>
Scott Lydiard's Brake Lever Alignment Template

<a title="Using Scott Lydiard's Front Brake Lever Alignment Template by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10857564963/"><img alt="Using Scott Lydiard's Front Brake Lever Alignment Template" src="http://farm4.staticflickr.com/3688/10857564963_e27c74c71f_z.jpg" width="640" height="480" /></a>
Using Scott Lydiard's Front Brake Lever Alignment Template

<a title="Front Axle and Insert by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10838870455/"><img alt="Front Axle with Spacer Sleeve" src="http://farm3.staticflickr.com/2860/10838870455_c5ae09e6de_z.jpg" width="640" height="480" /></a>
Front Axle with Spacer Sleeve

<a title="Front Brake Hub & Wheel Installed by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10838933186/"><img alt="Front Brake Hub, Brake Arm & Wheel Installed" src="http://farm8.staticflickr.com/7326/10838933186_ed4fe1bdf5_z.jpg" width="640" height="480" /></a>
Front Brake Hub, Brake Arm & Wheel Installed

<a title="Right Control Assembly with Front Brake Lever by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10857375564/"><img alt="Right Control Perch Assemble" src="http://farm4.staticflickr.com/3823/10857375564_3946cf6fc0_z.jpg" width="640" height="480" /></a>
Right Control Perch Assemble

<a title="Brake Cable Assembly in Right Control Perch by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10877244604/"><img alt="Brake Cable Assembly at Right Control Perch" src="http://farm4.staticflickr.com/3728/10877244604_5b52fa2e63_z.jpg" width="640" height="480" /></a>
Brake Cable Assembly at Right Control Perch

<a title="Inserting Ferrule in Brake Lever by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10880009073/"><img alt="Inserting Ferrule in Rear Brake Lever to Capture Outer Sleeve of the Cable" src="http://farm3.staticflickr.com/2841/10880009073_05a1403b18_z.jpg" width="640" height="480" /></a>
Inserting Ferrule in Rear Brake Lever to Capture Outer Sleeve of the Cable

<a title="Adjusting Lower Cable by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10879699335/"><img alt="Adjusting Lower Cable" src="http://farm6.staticflickr.com/5473/10879699335_0c69eb8e4d_z.jpg" width="640" height="480" /></a>
Adjusting Lower Cable

<a title="Adjusting Brake Cam by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10880005324/"><img alt="Adjusting Brake Cam for 4 mm Slack in Front Brake Lever" src="http://farm4.staticflickr.com/3691/10880005324_2beded7088_z.jpg" width="640" height="480" /></a>
Adjusting Brake Cam for 4 mm Slack in Front Brake Lever

<a title="Solid at 1/2 Distance by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10879698905/"><img alt="Brakes Are Solid at 1/2 Distance to Handlebar" src="http://farm3.staticflickr.com/2808/10879698905_e7918338a8_z.jpg" width="640" height="480" /></a>
Brakes Are Solid at 1/2 Distance to Handlebar

Best
Brook Reams
 
1973 R75/5 Rebuild, Install Electrical System

Folks,

I finished installing the electrical system and performed a smoke test. NO SMOKE :groovy

Here's the link to the write-up on how I did this part of the project.

It's starting to look like a motorcycle once again. Now I have to decide if I start work on restoring the paint or finish installing the engine (heads, cylinders, etc.)

In the meantime, here are a few of the many pictures included in the write-up. I took a lot of pictures to help show how the various branches of the wiring harness are routed.

<a title="Broken Wiring Harness Sheath by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10929022265/"><img alt="Broken Wiring Harness Sheath" src="http://farm3.staticflickr.com/2852/10929022265_74b3d7cd29_z.jpg" width="640" height="480" /></a>
Broken Wiring Harness Sheath

<a title="Corroded Small Starter Relay Wire to (+) Battery Terminal by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10929023235/"><img alt="Corroded Lug on Starter Relay Wire to (+) Battery Terminal" src="http://farm3.staticflickr.com/2844/10929023235_4c2cda00d3_z.jpg" width="640" height="480" /></a>
Corroded Lug on Starter Relay Wire to (+) Battery Terminal

<a title="Starter Relay Wiring by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10929078766/"><img alt="Starter Relay Wiring Notes" src="http://farm8.staticflickr.com/7358/10929078766_da63e36ec9_z.jpg" width="640" height="480" /></a>
Starter Relay Wiring Notes

<a title="Engine Wires Attached to Starter Relay by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10929023815/"><img alt="Engine Wires Attached to Starter Relay" src="http://farm6.staticflickr.com/5500/10929023815_b7f9ce07a9_z.jpg" width="640" height="480" /></a>
Engine Wires Attached to Starter Relay

<a title="Horn Assembly by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10929306923/"><img alt="Horn Assembly" src="http://farm6.staticflickr.com/5496/10929306923_d907769ff2_z.jpg" width="640" height="480" /></a>
Horn Assembly

<a title="Attaching Headlight Shell Gaskets by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10929022895/"><img alt="Attaching Headlight Shell Gaskets" src="http://farm4.staticflickr.com/3671/10929022895_40071114c7_z.jpg" width="640" height="480" /></a>
Attaching Headlight Shell Gaskets

<a title="Threading Headlight Wiring Harness Along Frame Backbone by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10929162264/"><img alt="Threading Main Wiring Harness From Headlight Along Frame Backbone" src="http://farm8.staticflickr.com/7407/10929162264_15290df2c5_z.jpg" width="640" height="480" /></a>
Threading Main Wiring Harness From Headlight Along Frame Backbone

<a title="Starting to Pull Rear Frame Wiring by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10929078486/"><img alt="Starting to Pull Rear Frame Wiring Branch Through Rear Frame Tube" src="http://farm8.staticflickr.com/7428/10929078486_66030f98e7_z.jpg" width="640" height="480" /></a>
Starting to Pull Rear Frame Wiring Branch Through Rear Frame Tube

<a title="Routing Neutral Switch & Oil Pressure (Through Hole in Frame Gusset) and Rear Brake Light Wires (Under Battery Box) by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10929020505/"><img alt="Routing Neutral Switch & Oil Pressure (Through Hole in Frame Gusset) and Rear Brake Light Wires (Under Battery Box)" src="http://farm6.staticflickr.com/5484/10929020505_d86f86cfe3_z.jpg" width="480" height="640" /></a>
Routing Rear Brake Light Wires (Under Battery Box)

<a title="Transmission Neutral Switch Wire by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10929160734/"><img alt="Transmission Neutral Switch Wire" src="http://farm4.staticflickr.com/3804/10929160734_ca429ed429_z.jpg" width="480" height="640" /></a>
Transmission Neutral Switch Wire Routing Underneath the Frame

<a title="Connect Battery (+) Cable to Starter by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10929302183/"><img alt="Connect Battery (+) Cable to Starter" src="http://farm4.staticflickr.com/3728/10929302183_483a4d0258_z.jpg" width="640" height="480" /></a>
Connect Battery (+) Cable to Starter Motor Solenoid

<a title="Starter Cable Routing Between Coils by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10951277463/"><img alt="Starter Cable Routing Between Coils" src="http://farm8.staticflickr.com/7363/10951277463_b226901e9d_z.jpg" width="640" height="480" /></a>
Starter Solenoid Cable Routing in Rubber Wire *Loom & Between Coils

<a title="Smoke Test - It's ALIVE! by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10982989385/"><img alt="Smoke Test Success - It's ALIVE!!!" src="http://farm8.staticflickr.com/7371/10982989385_3c2f5e3edc_z.jpg" width="640" height="480" /></a>
Smoke Test Success - It's ALIVE!!!
 
1973 R75/5 Rebuild, Install Engine Top End

Folks,

Well, this work is done and the bike is really looking like an airhead with it's ears in the wind :)

You can read about the work I did here:

  • 11 BMW R75/5 Install Engine Top End

Thanks to Oak Okleshen, Bob Fleischer, Tom Cutter, Duane Auscherman and Anton Lagiardier for publishing materials and answering questions. Any mistakes I made are mine and do not reflect on their publications or advice.

Next up is exhaust, carburetors and seat.

Here a samples of the pictures you'll find in the write-up.

<a title="Progress So Far by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/10972339764/"><img alt="Progress So Far" src="http://farm4.staticflickr.com/3732/10972339764_543df5800c_z.jpg" width="640" height="480" /></a>
Progress So Far-Ready To Install Engine Top End

<a title="Left Side Exhaust Cam and Follower by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11256690596/"><img alt="Left Side Exhaust Cam and Follower" src="http://farm8.staticflickr.com/7445/11256690596_59c0403f4c_z.jpg" width="640" height="480" /></a>
Exhaust Cam Showing Off-center Cam Follower

<a title="Broken Oil Control Ring :-( by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11256423766/"><img alt="Too Much Expansion Gets You a Broken Oil Control Ring :-(" src="http://farm3.staticflickr.com/2819/11256423766_3cb62b1910_z.jpg" width="640" height="480" /></a>
Too Much Expansion Gets You a Broken Oil Control Ring :-([/caption]

<a title="All Three Rings Installed with Top Of Ring Facing You by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11261810624/"><img alt="All Three Rings Installed with Top Of Ring Facing Top of Piston" src="http://farm6.staticflickr.com/5516/11261810624_8d1a968777_z.jpg" width="640" height="480" /></a>
All Three Rings Installed with Top Of Ring Facing Top of Piston

<a title="Correct Left Side Piston Orientation with "Vorn" Pointing to Front by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11261856703/"><img alt="Correct Left Side Piston Orientation with "Vorn" Pointing to Front" src="http://farm3.staticflickr.com/2867/11261856703_4da24007d2_z.jpg" width="640" height="480" /></a>
Correct Left Side Piston Orientation with "Vorn" Pointing to Front

<a title="Inserting Piston with Ring Compressor by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11261801606/"><img alt="Inserting Piston in Cylinder with Ring Compressor" src="http://farm8.staticflickr.com/7413/11261801606_5fceffe06a_z.jpg" width="640" height="480" /></a>
Inserting Piston in Cylinder with Ring Compressor

<a title="Hylomar on Engine Case by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11261765945/"><img alt="Hylomar on Engine Case" src="http://farm3.staticflickr.com/2892/11261765945_348529348d_z.jpg" width="640" height="480" /></a>
Hylomar on Engine Case

<a title="Wrist Pin and C-Clips by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11261800116/"><img alt="Frozen Wrist Pin and C-rings" src="http://farm6.staticflickr.com/5507/11261800116_e8b36ced7d_z.jpg" width="640" height="480" /></a>
Frozen Wrist Pin and C-rings

<a title="Push Rod Tube Drawn Tight to Engine Casing by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11261806204/"><img alt="Push Rod Tube Drawn Tight to Engine Casing" src="http://farm3.staticflickr.com/2876/11261806204_ed7420c931_z.jpg" width="640" height="480" /></a>
Push Rod Tube Rubber Drawn Tight to Engine Casing

<a title="Proper Orientation of Rocker Block (Slot Facing Outside of Head) and Nut by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11517293043/"><img alt="Proper Orientation of Rocker Block (Slot Facing Outside of Head) and Nut Boss on Face of Block" src="http://farm4.staticflickr.com/3678/11517293043_77787217d0_z.jpg" width="640" height="480" /></a>
Proper Orientation of Rocker Block (Slot Facing Outside of Head) and Nut Boss on Face of Block

<a title="Measuring Distance Between Rocker Blocks by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11517293323/"><img alt="Measuring Distance Between Rocker Blocks" src="http://farm4.staticflickr.com/3710/11517293323_0fe71a1db6_z.jpg" width="640" height="480" /></a>
Measuring Distance Between Rocker Blocks

<a title="View From the Saddle by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11517196514/"><img alt="View From the Saddle" src="http://farm4.staticflickr.com/3752/11517196514_267fb288b9_z.jpg" width="640" height="480" /></a>
View From the Saddle
 
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1973 R75/5 Rebuild, Install Exhaust and Sito Mufflers

Folks,

I installed new Sito mufflers on the cleaned up header pipes over the Christmas break. Here is the write-up.

  • 18 BMW R75/5 Install Exhaust System
The mufflers look to be nice quality and were easy to install. Everything lined up with no hassles. I'll see how well they wear as time goes by.

Next up, carburetor and cable installation.

Here are a couple of the pictures from the write-up.

<a title="Sito Muffler Parts by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11578400796/"><img alt="Sito Muffler Parts" src="http://farm6.staticflickr.com/5509/11578400796_227c08a324_z.jpg" width="640" height="480" /></a>
Sito Muffler Parts

<a title="Exhaust Header Pipes by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11577940984/"><img alt="Exhaust Header Pipes" src="http://farm6.staticflickr.com/5494/11577940984_5a4b975ab7_z.jpg" width="640" height="480" /></a>
Exhaust Header Pipes

<a title="Orientation of Exhaust Header Rings by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11578398606/"><img alt="Orientation of Exhaust Header Seal Rings" src="http://farm8.staticflickr.com/7450/11578398606_8d8ee69d73_z.jpg" width="640" height="480" /></a>
Orientation of Exhaust Header Seal Rings

<a title="Mounting Muffler Bracket to Bottom of Muffler by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11577825323/"><img alt="Mounting Muffler Bracket to Bottom of Muffler" src="http://farm3.staticflickr.com/2869/11577825323_ef55074392_z.jpg" width="640" height="480" /></a>
Mounting Muffler Bracket to Bottom of Muffler

<a title="Tightening Exhaust Header Nut by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11577939394/"><img alt="Tightening Exhaust Header Nut" src="http://farm8.staticflickr.com/7355/11577939394_c8e12848a5_z.jpg" width="640" height="480" /></a>
Tightening Exhaust Header Nut

<a title="Exhaust Installed by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11577824383/"><img alt="Sito Exhaust Installed" src="http://farm6.staticflickr.com/5520/11577824383_ddee7338ea_z.jpg" width="640" height="480" /></a>
Sito Exhaust Installed

<a title="New Sito Mufflers by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11577603105/"><img alt="Sito Exhaust Installed" src="http://farm4.staticflickr.com/3827/11577603105_1983d5575b_z.jpg" width="640" height="480" /></a>
Sito Exhaust Installed

<a title="New Sito Mufflers by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11578397726/"><img alt="Sito Exhaust Installed" src="http://farm8.staticflickr.com/7315/11578397726_a01db387ee_z.jpg" width="640" height="480" /></a>
Sito Exhaust Installed

Best.
Brook Reams
 
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1973 R75/5 Rebuild, Painting Engine Badges

Folks,

A short write-up on how I refreshed the engine badges.

  • 51 BMW R75/5 Paint Engine Badge
I hope this is helpful. It took me some time to polish up the lettering as there were faded areas on the letters, but it looks pretty nice now.

<a title=". by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11637706325/"><img alt="Quick Bench Top Paint Booth" src="http://farm8.staticflickr.com/7310/11637706325_ff6c623b92_z.jpg" width="640" height="480" /></a>
Quick Bench Top Paint Booth

<a title=". by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11637706495/"><img alt="Masked Starter Motor Cover" src="http://farm3.staticflickr.com/2879/11637706495_659276d2b1_z.jpg" width="640" height="480" /></a>
Masked Starter Motor Cover

<a title="Badge Painted with Black Brake Caliper Paint by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11638089364/"><img alt="Badge Painted with Black Brake Caliper Paint" src="http://farm8.staticflickr.com/7428/11638089364_bc08e4f4b9_z.jpg" width="640" height="480" /></a> Badge Painted with Black Brake Caliper Paint[/caption]

<a title="Baking at 200 F for 20 Minutes by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11638089084/"><img alt="Baking at 200 F for 20 Minutes" src="http://farm4.staticflickr.com/3811/11638089084_02a0c43f02_z.jpg" width="640" height="480" /></a>
Baking at 200 F for 20 Minutes


<a title=". by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11638473726/"><img alt="Repainted Engine Badge Installed" src="http://farm3.staticflickr.com/2858/11638473726_cdc0be03d1_z.jpg" width="640" height="480" /></a>
Repainted Engine Badge Installed
 
Outstanding documentation Brook, it almost makes me want to tear mine down again just to freshen things up a bit ... almost. And I'm glad to see your smoke test was successful, I was going to offer you some of the extra smoke that I had left over from mine... ..;)

What adhesive did you end up using for securing the engine plates?
 
Outstanding documentation Brook, it almost makes me want to tear mine down again just to freshen things up a bit ... almost. And I'm glad to see your smoke test was successful, I was going to offer you some of the extra smoke that I had left over from mine... ..;)

What adhesive did you end up using for securing the engine plates?

Hi Lew,

Thanks for the kind offer of the extra smoke for testing. With the recent legalization of MJ for personal use in Colorado, there is now a ready supply of same in these parts :)

I did not remove the badges, I painted them in place, so I can't advise on adhesive if you want to reattach. Somewhere in the back of my brain, "Gorilla Snot" has been mentioned for this.
http://boxerworks.com/forum/viewtopic.php?f=1&t=3561

If you do dive in for a "Freshen Up", I'm sure you will have a great experience.

Best.
Brook.
 
1973 R75/5 Rebuild, Installing Carburetors and Cables

Folks,

Well, one step closer to a "First Engine Start" on this project. Just about everything needed is done before trying to start the engine after seven years of hibernation.

I wrote-up putting the choke lever assembly back together, and installing the carburetor's and cables on the bike.

  • 13 BMW R75/5 Install Carburetors and Cables
But, work intervenes so back to earning a wage instead of the joy of bringing the bike back to life.

Here a couple pictures from the write-up.

<a title="Choke Assembly by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11638474026/"><img alt="Choke Assembly Parts" src="http://farm8.staticflickr.com/7330/11638474026_cfc5491cb5_z.jpg" width="640" height="480" /></a>
Choke Lever Parts

<a title="Choke Body and Cables Installed on Left Air Box Cover by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11638471236/"><img alt="Choke Body and Cables Installed on Left Air Box Cover" src="http://farm4.staticflickr.com/3774/11638471236_a8c4e7e131_z.jpg" width="640" height="480" /></a>
Choke Body and Choke Cables Installed on Left Air Box Cover

<a title="Back Side of Carburetor Showing Coke Cable Nipple Installation by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11638084864/"><img alt="Back Side of Carburetor Showing Coke Cable Nipple Installation" src="http://farm4.staticflickr.com/3718/11638084864_3f87ee20bb_z.jpg" width="480" height="640" /></a>
Back Side of Carburetor Showing Choke Cable Adjuster Installation

<a title="Alignment Marks on Throttle Cam & Twist Grip by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11675820436/"><img alt="Alignment Marks on Twist Grip & Throttle Cam" src="http://farm6.staticflickr.com/5484/11675820436_829cd312b3_z.jpg" width="640" height="480" /></a>
Alignment Marks on Twist Grip & Throttle Cam

<a title="Carburetor Vertical Alignment by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11659847114/"><img alt="Carburetor Vertical Alignment" src="http://farm3.staticflickr.com/2828/11659847114_4e86702aa7_z.jpg" width="640" height="480" /></a>
Carburetor Vertical Alignment

<a title="From the Saddle View of Carburetor and Cables Installed by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11637698235/"><img alt="From the Saddle View of Carburetor with Cables Installed" src="http://farm8.staticflickr.com/7318/11637698235_69e73ff1bf_z.jpg" width="640" height="480" /></a>
From the Saddle View of Carburetor with Cables Installed
 
1973 R75/5 Rebuild, Install New Plug Wires

Folks,

One other small bit of work completed on New Years day.

  • 12 BMW R75/5 Install Spark Plug Wires
At this point, I'm preparing for first engine start by going over what I've done and doing simple tests to try and find any mistakes and correct them.

Perhaps I'll be able to make a short video of the blessed event so you can join me in the celebration of bringing yet another airhead engine back to life :)

Here is what she looks like from the saddle at this point.

<a title="Plugs and Cables Installed by ScooterScum_52, on Flickr" href="http://www.flickr.com/photos/brook-reams/11675031935/"><img alt="Spark Plugs and Cables Installed" src="http://farm3.staticflickr.com/2831/11675031935_33a08cf094_z.jpg" width="640" height="480" /></a>
Spark Plugs and Cables Installed
 
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