1977 BMW R100RS Restore Project

[brook.reams]

1977 R100RS Project: Front End Rebuild

I've posted a series of write-ups that cover rebuilding the front end of this bike. You can find them here:
<ul class="children">
<li class="page_item page-item-4997"><a href="http://brook.wordpress.reams.me/bmw-motorcyle-rebuilds/1977-bmw-r100rs-rebuild-project-index/31-bmw-1977-r100rs-remove-front-forks-handle-bars-steering-stem-fork-lock/">31 BMW 1977 R100RS Remove Front Forks, Handle Bars, Steering Stem, Fork Lock</a></li>
<li class="page_item page-item-5044"><a href="http://brook.wordpress.reams.me/bmw-motorcyle-rebuilds/1977-bmw-r100rs-rebuild-project-index/31-bmw-1977-r100rs-replace-steering-head-bearings-rebuild-front-forks/">31 BMW 1977 R100RS Replace Steering Head Bearings, Rebuild Front Forks</a></li>
<li class="page_item page-item-4999"><a href="http://brook.reams.me/bmw-motorcyle-rebuilds/1977-bmw-r100rs-rebuild-project-index/31-bmw-1977-r100rs-install-steering-stem-front-forks-and-toaster-tan-top-brace/">31 BMW 1977 R100RS Install Steering Stem, Front Forks and Toaster Tan Top Brace</a></li>
<li class="page_item page-item-5006"><a href="http://brook.wordpress.reams.me/bmw-motorcyle-rebuilds/1977-bmw-r100rs-rebuild-project-index/34-bmw-1977-r100rs-rebuild-and-restore-front-disk-brakes-master-cylinder/">34 BMW 1977 R100RS Rebuild and Restore Front Disk Brakes & Master Cylinder</a></li>
<li class="page_item page-item-4869"><a href="http://brook.wordpress.reams.me/bmw-motorcyle-rebuilds/1977-bmw-r100rs-rebuild-project-index/36-bmw-1977-r100rs-wheel-bearings-remove-install-adjust-preload/">36 BMW 1977 R100RS Wheel Bearings-Replace & Adjust Preload</a></li>
</ul>
These write-ups cover disassembly of the handlebars, forks, steering stem, steering damper and fork lock, rebuilding and restoring the wheels, wheel bearings, fork damper rods, fork sliders, steering stem bearings, fork lock, steering damper and installation of a new <a href="http://toastertan.com/top_brace/" target="_blank">Toaster Tan top brace</a> and steering stem "acorn" nut.

I also have a couple of short videos included that show how I measure fork stiction as I assemble the forks and braces and how I measure the fork tube aligment in the X and Y axis.

I also used<a href="https://spieglerusa.com/brakes/brake-lines-accessories-tools/cycle-brake-line-kits/bmw-r-100-rs-front-brake-line-kit-112.htm" target="_blank"> Speigler braided steel brake hoses</a>, stainless steel caliper brake lines from <a href="https://www.rockypointcycle.com/c-bmw.html" target="_blank">Rocky Point Cycle</a>.


Here is what I started with.

<a title="Torn Top Plate of Left Perch" href="https://www.flickr.com/photos/brook-reams/33197659105/in/album-72157680932474765/"><img src="https://c1.staticflickr.com/4/3911/33197659105_0e77f4049e_z.jpg" alt="Torn Top Plate of Left Perch" width="640" height="426" /></a>
Torn Top Plate of Left Perch

<a title="Cover Plate Obstructs Lock Tumbler Preventing Removal" href="https://www.flickr.com/photos/brook-reams/33041689562/in/album-72157680932474765/"><img src="https://c1.staticflickr.com/4/3877/33041689562_65dd7496e7_z.jpg" alt="Fork Lock" width="640" height="426" /></a>
Fork Lock=
<a title="Front Wheel Left Side of Hub" href="https://www.flickr.com/photos/brook-reams/32374261866/in/album-72157677347336402/"><img src="https://c1.staticflickr.com/1/265/32374261866_4a9a36c416_z.jpg" alt="Front Wheel Left Side of Hub Showing Corrosion" width="640" height="480" /></a>
Front Wheel Left Side of Hub Showing Corrosion

<a title="Master Cylinder Mounted on Spine Tube" href="https://www.flickr.com/photos/brook-reams/33460100486/in/album-72157675789624605/"><img src="https://c1.staticflickr.com/3/2853/33460100486_de9c98b3a6_z.jpg" alt="Master Cylinder Grunge and Rust" width="640" height="426" /></a>
Master Cylinder Grunge and Rust

<a title="Original Caliper is Faded" href="https://www.flickr.com/photos/brook-reams/33117746100/in/album-72157675789624605/"><img src="https://c1.staticflickr.com/3/2937/33117746100_210d1f30cc_z.jpg" alt="Original Caliper is Faded, Axle is Rusty, Fork Lowers Chipped" width="640" height="480" /></a>
Original Caliper is Faded, Axle is Rusty, Fork Lowers Chipped

<a title="Sign Friction Material Is Separating from Steel Backing Plate" href="https://www.flickr.com/photos/brook-reams/29975504673/in/album-72157675789624605/"><img src="https://c1.staticflickr.com/6/5530/29975504673_ccf692c497_z.jpg" alt="Friction Material Is Separating from Steel Backing Plate" width="640" height="426" /></a>
Friction Material Is Separating from Steel Backing Plate

<a title="Exterior Fading" href="https://www.flickr.com/photos/brook-reams/29975501693/in/album-72157675789624605/"><img src="https://c1.staticflickr.com/6/5577/29975501693_0d6163e0e2_z.jpg" alt="Exterior Fading of Caliper Anodizing" width="640" height="426" /></a>
Exterior Fading of Caliper Anodizing

<a title="Telefix Fork Brace" href="https://www.flickr.com/photos/brook-reams/29995237771/in/album-72157673429384672/"><img src="https://c1.staticflickr.com/9/8675/29995237771_e21ac15b7d_z.jpg" alt="Telefix Fork Brace Needs Refinishing" width="640" height="426" /></a>
Telefix Fork Brace Needs Refinishing

<a title="Fork Brace & Fender Mount" href="https://www.flickr.com/photos/brook-reams/29995236791/in/album-72157673429384672/"><img src="https://c1.staticflickr.com/6/5348/29995236791_cf8a9a09be_z.jpg" alt="Stock Fork Brace-Fender Mount" width="640" height="426" /></a>
Stock Fork Brace-Fender Mount[/caption]



And here is what I ended up with.

<a title="Fork Lock Installed" href="https://www.flickr.com/photos/brook-reams/32352784434/in/album-72157680932474765/"><img src="https://c1.staticflickr.com/3/2808/32352784434_39d020494b_z.jpg" alt="Fork Lock Installed in Powder Coated Frame" width="640" height="480" /></a>
Fork Lock Installed in Powder Coated Frame

<img src="https://c1.staticflickr.com/4/3896/32440292483_34b4fc2629_z.jpg" alt="Powder Coated Front Wheel with New Wheel Bearings Ready to Roll" width="640" height="480" />
Powder Coated Front Wheel with New Wheel Bearings Ready to Roll

<a title="Painted Control Housings" href="https://www.flickr.com/photos/brook-reams/32501103183/in/album-72157680932474765/"><img src="https://c1.staticflickr.com/3/2857/32501103183_52d219cecc_z.jpg" alt="Repaired & Painted Control Housings" width="640" height="480" /></a>
Repaired & Painted Control Housings

<a title="Master Cylinder Mounted on Spine Tube" href="https://www.flickr.com/photos/brook-reams/32772912504/in/album-72157675789624605/"><img src="https://c1.staticflickr.com/3/2921/32772912504_797faccf25_z.jpg" alt="Rebuilt and Refinished Master Cylinder Mounted on Spine Tube" width="640" height="480" /></a>
Rebuilt and Refinished Master Cylinder Mounted on Spine Tube

<a title="Toaster Tan Top Plate Mounted" href="https://www.flickr.com/photos/brook-reams/32615276323/in/album-72157673429384672/"><img src="https://c1.staticflickr.com/3/2837/32615276323_ec15f55f2e_z.jpg" alt="Toaster Tan Top Plate & Steering Stem "Acorn" Nut Mounted" width="640" height="480" /></a>
Toaster Tan Top Plate & Steering Stem "Acorn" Nut Mounted

<a title="Toaster Tan Top Plage" href="https://www.flickr.com/photos/brook-reams/32586749574/in/album-72157673429384672/"><img src="https://c1.staticflickr.com/1/755/32586749574_50e1848898_z.jpg" alt="Toaster Tan Top Plate" width="640" height="480" /></a>
Toaster Tan Top Plate

<a title="Stock Fork-Fender Brace" href="https://www.flickr.com/photos/brook-reams/33807460562/in/album-72157673429384672/"><img src="https://c1.staticflickr.com/4/3937/33807460562_67386b6915_z.jpg" alt="Stock Fork-Fender Brace Mounted on Rebuilt Forks" width="640" height="480" /></a>
Stock Fork-Fender Brace Mounted on Rebuilt Forks

<img src="https://c1.staticflickr.com/3/2928/33479600611_fc658c95a0_z.jpg" alt="Speigler Braided Steel & Rocky Point Cycle Stainless Aluminum Caliper Line" width="640" height="480" />
Speigler Braided Steel & Rocky Point Cycle Stainless Aluminum Caliper Line

 

[barryg]

A motorcycle is just endless little mechanisms all hooked together to function as one large complete unit. Looking good Brook.

 

[brook.reams]

A motorcycle is just endless little mechanisms all hooked together to function as one large complete unit. Looking good Brook.

Yeap, but it's the "hooked together" part that is interesting as that can range from 0.1 to 0.0005 inches. That's what fascinating.

Best.
Brook.

 

[barryg]

My old Starret micrometers even measured down to 0.0001 on the vernier scale. Small stuff indeed. I also used a height gage with dial readout to check those diamensions. Now everything is digital.

 

[barryg]

Brooke, what paint brand did you use to paint your calipers. I need to paint the calipers on my R90 Bagger project. Some type of dark gray or black. Any thoughts, thanks. Barry

 

[brook.reams]

Brooke, what paint brand did you use to paint your calipers. I need to paint the calipers on my R90 Bagger project. Some type of dark gray or black. Any thoughts, thanks. Barry

Hi Barry,

As I usually do, I include that information in the write-up. Take a look-see, but IIRC, it was from Dupli-color.

Best.
Brook.

 

[brook.reams]

1977 BMW R100RS Top End Rebuild Finished

I completed the rebuild of the top end and documented it in these write-ups.

• 11 BMW 1977 R100RS Remove Pistons, Connecting Rods & Inspect
• 11 BMW 1977 R100RS Replace Rocker Needle Bearings, Remove Valves & Inspect
• 11 BMW 1977 R100RS Install Connecting Rods and Assemble Top End

The work I did included removing heads, valves, rocker arm bearings, cylinders, pistons, rings and connecting rods. The bike has Nikasil cylinders (not original to the bike) with low compression (8.2:1) pistons. The rocker arm bearing cages were broken on two rocker arms, one of the rod bearings was scored, and several valve faces were thin.

I sent the cylinders and high compression (9.5:1) pistons and rings, connecting rods and the heads to Tom Cutter for the necessary machining and work. When I got everything back, I put it all back together. So, another major milestone on the project has been met. But, the clock is still ticking to get done before September .....

Here are some pictures from the write-ups of what I started with and the completed assembly of the top end.

<a title="Ready To Remove Heads & Cylinders" href="https://www.flickr.com/photos/brook-reams/31366903026/in/album-72157675205320686/"><img src="https://c1.staticflickr.com/6/5710/31366903026_4ec02a0594_z.jpg" alt="Ready To Remove Heads & Cylinders" width="640" height="426" /></a>
Ready To Remove Heads & Cylinders

<a title="Engine Out of Frame" href="https://www.flickr.com/photos/brook-reams/30800499320/in/album-72157675205320686/"><img src="https://c1.staticflickr.com/6/5685/30800499320_27cd8d438b_z.jpg" alt="Engine Out of Frame" width="640" height="426" /></a>
Engine Out of Frame

<a title="Piston Crown with Carbon" href="https://www.flickr.com/photos/brook-reams/30655833004/in/album-72157675205320686/"><img src="https://c1.staticflickr.com/1/662/30655833004_a387726085_z.jpg" alt="Piston Crown with Carbon" width="640" height="480" /></a>
Piston Crown with Carbon

<a title="Rod Components" href="https://www.flickr.com/photos/brook-reams/31496778615/in/album-72157675205320686/"><img src="https://c1.staticflickr.com/1/329/31496778615_bafebd31f1_z.jpg" alt="Rod Components" width="640" height="480" /></a>
Rod Components

<a title="Score in Right Cap Bearing Sheel" href="https://www.flickr.com/photos/brook-reams/31496778175/in/album-72157675205320686/"><img src="https://c1.staticflickr.com/1/547/31496778175_5998ab9e57_z.jpg" alt="Score in Right Cap Bearing Sheel" width="640" height="480" /></a>
Score in Right Cap Bearing Sheel

<a title="Right Side Crankshaft Throw" href="https://www.flickr.com/photos/brook-reams/31280231910/in/album-72157675205320686/"><img src="https://c1.staticflickr.com/1/759/31280231910_5dff368d9f_z.jpg" alt="Right Side Crankshaft Throw" width="640" height="480" /></a>
Right Side Crankshaft Throw

<a title="Cylinder Grunge" href="https://www.flickr.com/photos/brook-reams/31557867491/in/album-72157675205320686/"><img src="https://c1.staticflickr.com/1/400/31557867491_8597d08952_z.jpg" alt="Cylinder Grunge" width="640" height="480" /></a>
Cylinder Grunge

<a title="Left Exhaust Lower Rocker-Recovered Needle Bearings and Cage Pieces" href="https://www.flickr.com/photos/brook-reams/29741461684/in/album-72157671786788374/"><img src="https://c1.staticflickr.com/9/8592/29741461684_50122d53b9_z.jpg" alt="Left Exhaust Lower Rocker-Recovered Needle Bearings and Cage Pieces" width="640" height="426" /></a>
Left Exhaust Lower Rocker-Recovered Needle Bearings and Cage Pieces

<a title="Right Intake Rocker Busing" href="https://www.flickr.com/photos/brook-reams/29740137723/in/album-72157671786788374/"><img src="https://c1.staticflickr.com/6/5757/29740137723_6593d4200f_z.jpg" alt="Right Intake Rocker Busing" width="640" height="426" /></a>
Right Intake Rocker Busing

<a title="Right Intake Rocker Shaft" href="https://www.flickr.com/photos/brook-reams/29740137233/in/album-72157671786788374/"><img src="https://c1.staticflickr.com/9/8140/29740137233_c467465d87_z.jpg" alt="Right Intake Rocker Shaft" width="640" height="426" /></a>
Right Intake Rocker Shaft

<a title="Valve Assembly Components" href="https://www.flickr.com/photos/brook-reams/31652878166/in/album-72157671786788374/"><img src="https://c1.staticflickr.com/6/5562/31652878166_c212b77cd6_z.jpg" alt="Valve Assembly Components" width="640" height="480" /></a>
Valve Assembly Components


Here is what I ended up with.


<a title="Push Rod Tubes Installed" href="https://www.flickr.com/photos/brook-reams/34195856461/in/album-72157675205320686/"><img src="https://c1.staticflickr.com/3/2893/34195856461_721933658e_z.jpg" alt="Push Rod Tubes Installed" width="640" height="480" /></a>
Push Rod Tubes Installed

<a title="Piston with Rings Installed" href="https://www.flickr.com/photos/brook-reams/33722306754/in/album-72157675205320686/"><img src="https://c1.staticflickr.com/5/4159/33722306754_7d48782fce_z.jpg" alt="Piston with Rings Installed" width="640" height="480" /></a>
Piston with Rings Installed

<a title="Sliding Cylinder and Piston onto Long Cylinder Studs" href="https://www.flickr.com/photos/brook-reams/34384103172/in/album-72157675205320686/"><img src="https://c1.staticflickr.com/5/4174/34384103172_7c21c6642d_z.jpg" alt="Sliding Cylinder and Piston onto Long Cylinder Studs" width="640" height="480" /></a>
Sliding Cylinder and Piston onto Long Cylinder Studs

<a title="Ready to Snug Cylinder to Engine Block-Push Rod Tube Rubbers Started" href="https://www.flickr.com/photos/brook-reams/33734474053/in/album-72157675205320686/"><img src="https://c1.staticflickr.com/5/4194/33734474053_ea07d66ee2_z.jpg" alt="Ready to Snug Cylinder to Engine Block-Push Rod Tube Rubbers Started" width="640" height="480" /></a>
Ready to Snug Cylinder to Engine Block-Push Rod Tube Rubbers Started

<a title="Left Head Orientation-Exhaust to Front" href="https://www.flickr.com/photos/brook-reams/33734472993/in/album-72157675205320686/"><img src="https://c1.staticflickr.com/5/4191/33734472993_ca7ed699e1_z.jpg" alt="Left Head Orientation-Exhaust to Front" width="640" height="480" /></a>
Left Head Orientation-Exhaust to Front

<a title="Top End Installed" href="https://www.flickr.com/photos/brook-reams/34159231170/in/album-72157675205320686/"><img src="https://c1.staticflickr.com/5/4191/34159231170_fd348cb0b6_z.jpg" alt="Top End Installed" width="640" height="480" /></a>
Top End Installed

<a title="Valve Cover Installed" href="https://www.flickr.com/photos/brook-reams/34543103676/in/album-72157675205320686/"><img src="https://c1.staticflickr.com/5/4161/34543103676_1f11338bdf_z.jpg" alt="Valve Cover Installed" width="640" height="480" /></a>
Valve Cover Installed

 

[brook.reams]

1977 BMW R100RS Cleaning Up The Electrical Wiring and Components

The wiring was in dire need of either replacement or refurbishment.

<a title="Starter Relay Contact Corrosion" href="https://www.flickr.com/photos/brook-reams/33903071344/in/album-72157674599790006/"><img src="https://c1.staticflickr.com/5/4198/33903071344_b70bb151a6_z.jpg" alt="Starter Relay Contact Corrosion - Green and Gruesome " width="640" height="426" /></a>
Starter Relay Contact Corrosion - Green and Gruesome

<a title="Starter Relay Wire from Battery-Grungy" href="https://www.flickr.com/photos/brook-reams/34360689240/in/album-72157674599790006/"><img src="https://c1.staticflickr.com/5/4179/34360689240_30a596e1df_z.jpg" alt="Starter Relay Wire from Battery (+) Cable-Grungy" width="640" height="426" /></a>
Starter Relay Wire from Battery (+) Cable-Grungy

<a title="Starter Relay Wires Removed" href="https://www.flickr.com/photos/brook-reams/34360688920/in/album-72157674599790006/"><img src="https://c1.staticflickr.com/5/4158/34360688920_f55eb9f6aa_z.jpg" alt="Starter Relay Wires Removed (Brown Wires are Really Red)" width="640" height="426" /></a>
Starter Relay Wires Removed (Brown Wires are Really Red)

I have posted two write-ups. The first is about how I removed all the wiring and electrical components.
<ul class="children">
<li class="page_item page-item-5286"><a href="http://brook.reams.me/bmw-motorcyle-rebuilds/1977-bmw-r100rs-rebuild-project-index/61-bmw-1977-r100rs-remove-wiring-harness-instruments-electrical-components/">61 BMW 1977 R100RS Remove Wiring Harness, Instruments & Electrical Components</a></li>
</ul>
The second covers how I refurbished the wiring getting rid of grunge, green corrosion and repaired terminals, and then how I installed the main harness, sub-harness' and electrical components.
<ul class="children">
<li class="page_item page-item-5227"><a href="http://brook.reams.me/bmw-motorcyle-rebuilds/1977-bmw-r100rs-rebuild-project-index/61-bmw-1977-r100rs-refurbish-main-wire-harness-install-electrical-components/">61 BMW 1977 R100RS Refurbish and Install Wiring & Electrical Components</a></li>
</ul>
I also shot a video showing how I routed the wiring.

 

[barryg]

Looking good, Brook. I'm enjoying your progress on the project.

 

[brook.reams]

Looking good, Brook. I'm enjoying your progress on the project.

Thanks Barry.

Best.
Brook.

 

[Omega Man]

Interesting on the white vinegar for cleaning the wire terminals.....never tried it. I usually use a .22cal brass cleaning brush in a cordless drill. I'll have to try the vinegar tip
Gary

 

[brook.reams]

Interesting on the white vinegar for cleaning the wire terminals.....never tried it. I usually use a .22cal brass cleaning brush in a cordless drill. I'll have to try the vinegar tip
Gary

Hi Gary,

It got the metal bright, although I also used a brass wire brush to help the get them clean. It's important to dip them into baking soda solution afterwards to neutralize the acid.

Best.
Brook.

 

[brook.reams]

1977 BMW R100RS Assembling and Installing Fairing, Dash, Seat and Cowl

I just published two new write-ups; one on installing the fairing and the other on assembling the cowl and seat and installing them. *Here are links to them.
<ul class="children">
<li class="page_item page-item-5269"><a href="http://brook.reams.me/bmw-motorcyle-rebuilds/1977-bmw-r100rs-rebuild-project-index/46-bmw-1977-r100rs-assemble-fairing-dash-instruments-and-windscreen/">46 BMW 1977 R100RS Assemble Fairing, Dash, Instruments and Windscreen</a></li>
<li class="page_item page-item-5416"><a href="http://brook.reams.me/bmw-motorcyle-rebuilds/1977-bmw-r100rs-rebuild-project-index/52-bmw-1977-r100rs-assemble-and-install-seat-and-cowl/">52 BMW 1977 R100RS Assemble and Install Seat and Cowl</a></li>
</ul>Next, I'm working on a write-up that shows how I assembled the bike starting with the frame through the gas cap.

Here are pictures of the final results.

<a href="https://www.flickr.com/photos/brook-reams/36298083851/in/album-72157684884323780/"><img src="https://farm5.staticflickr.com/4425/36298083851_ae389723ef_z.jpg" alt="Clear View Wind Screen & Headlight Lens Installed" width="640" height="480" /></a>
Faring, Windscreen and Mirrors Installed

<a title="Dash and Instruments Installed" href="https://www.flickr.com/photos/brook-reams/35600126704/in/album-72157684884323780/"><img src="https://farm5.staticflickr.com/4346/35600126704_d3d9f88609_z.jpg" alt="Cockpit View" width="640" height="480" /></a>
Cockpit View

<a title="Fairing Installed" href="https://www.flickr.com/photos/brook-reams/35600125714/in/album-72157684884323780/"><img src="https://farm5.staticflickr.com/4333/35600125714_319ba61861_z.jpg" alt="View From Seat" width="640" height="480" /></a>
View From Seat

<a title="Fairing and Body Work Installed" href="https://www.flickr.com/photos/brook-reams/36266724542/in/album-72157684884323780/"><img src="https://farm5.staticflickr.com/4359/36266724542_3bcd2bacd0_z.jpg" alt="Right Side View" width="640" height="480" /></a>
Right Side View

<a href="https://www.flickr.com/photos/brook-reams/36266730882/in/album-72157684923129453/"><img src="https://farm5.staticflickr.com/4416/36266730882_d00434708f_z.jpg" alt="Rear Cowl Decal and Rondel Installed" width="640" height="480" /></a>
Rear Cowl Decal and Roundel Installed

A far cry from what I started with:

<a title="Headlight Panel Cracks" href="https://www.flickr.com/photos/brook-reams/29127953980/in/album-72157672306851951/"><img src="https://farm9.staticflickr.com/8538/29127953980_ef6bd2aa8a_z.jpg" alt="Headlight Panel Cracks Are Extensive" width="640" height="426" /></a>
Headlight Panel Cracks Are Extensive

<a href="https://www.flickr.com/photos/brook-reams/29127953790/in/album-72157672306851951/"><img src="https://farm9.staticflickr.com/8384/29127953790_5c76b23d76_z.jpg" alt="Headlight Panel Cracks" width="640" height="426" /></a>
Headlight Panel Cracks

<a title="Upper Side Panel Large Crack" href="https://www.flickr.com/photos/brook-reams/29564213431/in/album-72157673798772405/"><img src="https://farm9.staticflickr.com/8383/29564213431_60a6440a4a_z.jpg" alt="Top Side Panel Large Crack" width="640" height="426" /></a>
Top Side Panel Large Crack

<a href="https://www.flickr.com/photos/brook-reams/26331843556/in/album-72157666863178492/"><img src="https://farm2.staticflickr.com/1615/26331843556_b33502f359_z.jpg" alt="Windscreen Damage" width="640" height="426" /></a>
Windscreen Damage

<a title="Tail Damage" href="https://www.flickr.com/photos/brook-reams/25752945824/in/album-72157666863178492/"><img src="https://farm2.staticflickr.com/1480/25752945824_4aa0bc613b_z.jpg" alt="Seat Cowl Dent" width="640" height="480" /></a>
Seat Cowl Dent

 

[Darryl Cainey]

You have done a great job so far.

Just a note: Your handle bar clamps should be polished aluminum.

 

[brook.reams]

You have done a great job so far.

Just a note: Your handle bar clamps should be polished aluminum.

Hi Darryl,

No, I'm happy with color contrast. It also doesn't have the dash either

Best.
Brook.

 

[brook.reams]

1977 BMW R100RS Assembling The Bike From the Frame to the Gas Cap

I completed assembling the bike from the frame through the gas cap and put together a write-up that shows the order in which I assembled it. You will find the write-up here:
<ul class="children">
<li class="page_item page-item-5349 current_page_item"><a href="http://brook.reams.me/bmw-motorcyle-rebuilds/1977-bmw-r100rs-rebuild-project-index/00-bmw-1977-r100rs-assembling-the-bike-from-the-frame-up/">00 BMW 1977 R100RS Assembling The Bike From the Frame Up</a></li>
</ul>
It includes assembly of the front forks, seat, fenders, battery box, installation of the handlebars and cables, and odds and ends that I felt were better covered in this write-up rather in a separate one following the parts fiche breakdown I use for cataloging my write-ups. I include links to other write-ups where applicable to explain a particular procedure.

Here is a short video of a walk-around of the finished bike followed by some pictures.

<a title="Rear Cowl Decal and Rondel Installed" href="https://www.flickr.com/photos/brook-reams/36266730882/in/album-72157684154125352/"><img src="https://farm5.staticflickr.com/4416/36266730882_d00434708f_z.jpg" alt="Rear Cowl Decal and Roundel" width="640" height="480" /></a>
Rear Cowl Decal and Roundel

<a title="Inspection Sticker and Tire Information Stickers" href="https://www.flickr.com/photos/brook-reams/36266731092/in/album-72157684154125352/"><img src="https://farm5.staticflickr.com/4436/36266731092_d85482f3ec_z.jpg" alt="Inspection Sticker, Tire Information Sticker, Seat Sticker " width="640" height="480" /></a>
Inspection Sticker and Tire Information Sticker (From Heritage Stickers)& Original Seat Sticker

<a href="https://www.flickr.com/photos/brook-reams/35600126704/in/album-72157684154125352/"><img src="https://farm5.staticflickr.com/4346/35600126704_d3d9f88609_z.jpg" alt="Cockpit with Instruments and Original Dash Stickers" width="640" height="480" /></a>
Cockpit with Instruments and Original Dash Stickers

<a title="Finished Bike-Carburetor" href="https://www.flickr.com/photos/brook-reams/36548804966/in/album-72157684154125352/"><img src="https://farm5.staticflickr.com/4413/36548804966_b7f48db3bc_z.jpg" alt="Carburetor, Tygon Fuel Lines, Engine Badge and Polished Engine Housing" width="640" height="480" /></a>
Carburetor, Tygon Fuel Lines, Engine Badge and Polished Engine Housing

<a href="https://www.flickr.com/photos/brook-reams/36298083851/in/album-72157684154125352/"><img src="https://farm5.staticflickr.com/4425/36298083851_ae389723ef_z.jpg" alt="Clear View Windscreen with Stock Mirrors" width="640" height="480" /></a>
Clear View Windscreen with Stock Mirrors

<a title="Finished Bike-Right Front" href="https://www.flickr.com/photos/brook-reams/36595105835/in/album-72157684154125352/"><img src="https://farm5.staticflickr.com/4344/36595105835_18e960aaaf_z.jpg" alt="Finished Bike-Right Front" width="480" height="640" /></a>
Finished Bike-Left Front

<a href="https://www.flickr.com/photos/brook-reams/36548804506/in/album-72157684154125352/"><img src="https://farm5.staticflickr.com/4407/36548804506_588a41d8e3_z.jpg" alt="Finished Bike-Right Rear" width="640" height="480" /></a>
Finished Bike-Right Rear

<a title="Finished Bike-Rear" href="https://www.flickr.com/photos/brook-reams/36595104905/in/album-72157684154125352/"><img src="https://farm5.staticflickr.com/4428/36595104905_96980e540d_z.jpg" alt="Finished Bike-Rear" width="640" height="480" /></a>
Finished Bike-Rear

<a href="https://www.flickr.com/photos/brook-reams/36266724542/in/album-72157684154125352/"><img src="https://farm5.staticflickr.com/4359/36266724542_3bcd2bacd0_z.jpg" alt="Finished Bike-Left Side" width="640" height="480" /></a>
Finished Bike-Left Side

<a title="Fairing Installed" href="https://www.flickr.com/photos/brook-reams/35600125714/in/album-72157684154125352/"><img src="https://farm5.staticflickr.com/4333/35600125714_319ba61861_z.jpg" alt="Finished Bike-Seat View" width="640" height="480" /></a>
Finished Bike-Seat View

<a href="https://www.flickr.com/photos/brook-reams/36548806156/in/album-72157684154125352/"><img src="https://farm5.staticflickr.com/4442/36548806156_649185ee9f_z.jpg" alt="Finished Bike-Side Cover" width="640" height="480" /></a>
Finished Bike-Side Cover

<a title="Finished Bike-Left Rear" href="https://www.flickr.com/photos/brook-reams/35785558373/in/album-72157684154125352/"><img src="https://farm5.staticflickr.com/4358/35785558373_45086d27b5_z.jpg" alt="Finished Bike-Left Rear" width="640" height="480" /></a>
Finished Bike-Left Rear

<a href="https://www.flickr.com/photos/brook-reams/35785558773/in/album-72157684154125352/"><img src="https://farm5.staticflickr.com/4432/35785558773_09ea76a090_z.jpg" alt="Finished Bike-Left Front Side" width="640" height="480" /></a>
Finished Bike-Left Front Side

<a title="At the Coffee Shop For a Test Ride" href="https://www.flickr.com/photos/brook-reams/36594967985/in/album-72157684154125352/"><img src="https://farm5.staticflickr.com/4402/36594967985_ae81ba2b0f_z.jpg" alt="On a Test Ride to my Local Coffee Shop" width="640" height="360" /></a>
On a Test Ride to my Local Coffee Shop (w/ valve covers on the wrong way, since fixed )

 

[dbrick]

That's gorgeous, Brook. Thanks for sharing it!

 

[robsryder]

Brook - I am looking forward to seeing you and the bike at the soon-to-occur 40th anniversary gathering for the RS.

Please be careful riding across the country.

As I understand it, the organizer of this event still has openings. This will be a once-in-a-lifetime celebration of
the BMW RS bike. Other airheads may wish to attend. I have cut and pasted info on registration for this event
below (Sept 14-17 in Harleysville, Pa).

--- attachment follows ---

Hello to all R100RS enthusiasts and attendees of the upcoming 40th
Anniversary event.



Registration has formally begun and you have several choices in which to
register:



1. Click on the link below for Eventbrite, follow instructions, they
can accept your credit card, the amount is $95 plus small fee for this
service.



https://www.eventbrite.com/e/r100rs-40th-anniversary-tickets-36983364238



2. Use PayPal service "payment, person to person" $95, no service
fee. Please use this email address: motorrader@verizon.net. Please take
note, you must have a PayPal account, which is very easy to do.

3. Check or Money Order payable in the amount of $95. to:

Todd Trumbore

828 Salfordville Road

Harleysville, PA 19438

--- attachment follows ---

R100RS 40th Anniversary Celebration

14-17 September 2017

Harleysville, Montgomery County, Pennsylvania 19438



Celebrating Hans A. Muth's "Silver Daughter"



Dear R100RS enthusiasts,

I hope you are all doing well. It has been almost two years since I
started preparing for this event and now the time is growing closer and
closer, so I would like to update everyone on the latest news and begin a
formal registration process.

In June of 2014 Hans Muth joined us along with Udo Gietl , Reg Pridmore,
Gary Fisher, Todd Schuster and Tom Cutter to celebrate the 40th Anniversary
of the R90S. Robert Lutz went to the studio to produce a 20 minute video
explaining the genesis of the R90S and how this machine saved the day for
BMW Motorrad. It was a really nice gathering of riders from all corners of
the U.S.A., Canada, and a few from Europe and Australia. Hans really
enjoyed himself and expressed an interest in returning.

In September of 2015 he reminded me, that we were soon approaching another
anniversary of one of his proudest creations, the R100RS, which first
appeared in our dealerships as a 1977 model. He made it clear, that if we
were to have another gathering to celebrate his "Silver Daughter" , as he
refers, he would like to be at the top of the list.

Soon thereafter planning began. So, Hans Muth is returning this September,
along with him will be Klaus Herder, Editor of Motorrad Magazine and Hans
Joachim Siebenrock and his wife . Udo Gietl and Tom Cutter also plan on
attending, unfortunately Todd Schuster is having a tough battle with
diabetes and his health will not allow him to join us.

Sandy Cohen recently published Hans Muth's manuscripts and plans to join us.
Most BMW MOA members will remember Sandy's work, she is now the Editor in
Chief of BMW Motorcycle Magazine. There is a possibility that Fred Jakobs
of BMW Group Archives/Classics may make an appearance along with staff from
BMW of North America, no confirmation on that as yet. Bob Henig of Bob's
BMW and Max Stratton of Max BMW have been invited and plan on attending.

This event is being held at my private residence in the rolling hills of
rural Montgomery County, the southeast region of Pennsylvania. My property
is surrounded by forest/woods, so there should be plenty of shaded camping
for those who choose to camp. The riding in this area is very good with
many windy, twisty country roads that wrap around the hills, valleys,
streams , lakes and mountains to the north.

Due to the logistics, this event has been limited to 150 R100RS
riders/owners/enthusiasts. So this is a small private setting and rare
opportunity to engage in personal conversations with our guests. Please
bring any questions you may have regarding the RS with you. Hans and the
rest of our guests will be happy to answer any of your questions. All
attendees will receive:

Commemorative cloisonné medallion

Friday and Saturday Evening Catered Dinner

Camping with Showers included

Presentations and Autograph sessions by our Special Guests

Tech Session by Master Mechanic Karl Myers of Hermy's BMW

Live Musical Entertainment both Friday and Saturday evenings

Motorrad Movies under the Pavilion on the Flat Screen , evenings

Commemorative Key Chains, T-Shirts, Posters and Coffee Mugs available

Campfire under the Stars where Incredible Tales of Tall Proportions will be
Unfolded

The event will officially kick off Thursday evening, when Dave Wood will be
serving a giant pot of his famous Chili and Brats around the campfire to
welcome all the riders and to help them unwind after a long days ride. No
alcoholic beverages served, but you are welcome to provide your own as long
as you drink responsibly. Riders are welcome to arrive any time on
Thursday.

Bruce Brown and Dave Wood will be serving breakfast Friday and Saturday
morning along with coffee and donuts from 7:00-8:30 am. Joe Rotondi of the
Skippack Village Italian Market will here serving lunch on both Friday and
Saturday. Joe provided this service for our R90S event as well. Laura and
Dr. Susan will be wearing many hats once again, catering to all of your
needs and answering any questions or concerns. A few volunteers from the
BMW Riders of the Delaware Valley Club will also be present to assist in any
way they can.

Presentations from our special guests will be from around 9:00 am till noon
on Friday and Saturday, followed by autograph sessions and tire kicking.
All those who attended the R90S event know, that our special guests were
very generous in signing just about anything presented to them, i.e. side
covers, seat cowls, fairings, fuel tanks, t-shirts, posters, etc.
Reminder...bring your own Sharpie!

Master Mechanic Karl Myers will at some point, most likely Saturday
afternoon, perform one of his famous tech sessions where he will disassemble
an attendees RS down to the last nut and bolt, explaining the function of
each component along the way. With any luck at all the bike just may be
back together by the time the rally ends.

ABC Airmarshals from PA, NJ and NY will be in attendance and Dave Cushing
plans to set up the Airstore with various items for sale

My fifty year collection of motorbikes will be on display in the Bavarian
Bike Barn and historian, mechanic and curator, Mike Casale will offer a tour
of a private collection of vintage motorbikes and motorcars in nearby
Skippack Village. There will be a small fee for this tour, but this is a
unique opportunity to see a truly incredible, rare collection housed in
several private museums, plus the decor is almost as amazing as the vintage
machinery itself.

Peter Brunner is the Product Developer at Schuco, manufacturers of high
quality models most of you are familiar with and may own. Peter is the
proud owner of a 1979 blue/silver R100RS and his company recently unveiled
a 1:10 scale version of this wonderful machine. Peter has graciously
donated five of these RS models for our event, to be auctioned off for a
good cause. I have decided to donate the proceeds of these auctioned
R100RS models to Todd Schuster who is struggling to keep up with his
mounting medical bills.

Okay, now is when I need your help. I have invested hundreds and hundreds
of hours into planning this event over the past two years. I retired from
my job in early March and have devoted every day and night, almost without
exception, to prepare for this event both administratively and with site
preparation. My expenses for the R90S event were over $18,000, I expect my
expenses for this event to exceed that amount nearing $20,000 as I am
responsible for several more overseas airfares. These are borrowed funds
from a line of credit, my revenues will not come close to matching my
expenses, I hope to make some of this up through the sales of commemorative
items, but I doubt very much that I will break even...that's alright, I
didn't expect to. But....I do need to know who is attending and very, very
soon.

Everyone receiving this email posting has at some point in time over the
past two years signed up and said they wanted to attend this R100RS
Anniversary Event. Now before I initiate a formal registration, I need a
YES or a NO . I expect to set the registration fee at $95. for the four
day event I think that is a bargain. One enterprising fellow who purchased
an extra commemorative key chain from the R90S event placed it on an
internet auction and received over $150 for the item, well above his rally
fee.

So, before I turn this registration process over to Eventbrite, I need to
hear from all who plan on attending. If enough of you respond favorably, I
will allow Eventbrite to handle the formal registration process. They can
accept your credit cards, I am not equipped for that. Pre-registration is
mandatory, as I cannot afford to take on the financial risk without any
commitments.

I hope to hear from all of you soon and hope to see you here on the 14th of
September.

Happy Motoring,

Todd Trumbore

motorrader@verizon.net

 

[8ninety8]

Great attention to details, great plastic work, paint is perfect, mechanical spot on and shop as always imaculate, compared to mine. Now tell how it rides.

 

[toooldtocare]

Beautiful, just beautiful. Be proud of that bike.