Rebuild novice takes on 1976 R75/6

[themadp]

I will admit to being a little intimidated by this next project, its my first BMW and my first restoration.

B1 (my bikes don't get names until finished) is a BMW R75/6 built in 1976 that has not run since 1992.. that’s almost 20 years or storage in various environments so there is a lot of warn out rubber, seals etc. and because the previous owner(s) had thought to renovate her themselves there are more than a few mislaid bits and bolts.

At the beginning of any restoration project, faced with a vehicle covered in rust and bird poo there is an exciting mix of hope, its just surface rust, and fear, this could get expensive. Who knows what surprises this bike holds, why was she stored? Did her owner simply not have time to ride or did a mechanical failure cause her to be benched?

Discovering her secrets and getting her back on the road is going to be fun. As she only has 56k miles on the clock I’m optimistic, these bikes have a reputation for being very reliable, for a BMW Airhead like this 56k is just getting worn in.

Famous last words…

 

[themadp]

I have a cunning plan

My initial intention when I purchased the BMW was to build a custom airhead, something unique, something caf?®/bobber. Closest bikes to what I had in mind :

Traditionalists, breath.. the more I look at her the more unsure I become that I want to go that route. The friend who sold me this bike loves these bikes “as BMW built them” and is sure that if I ride her for a bit I will also fall in love with her foibles and looks. I’m open to the possibility; airheads are beautifully simple honest bikes both esthetically and mechanically.

Therefore, my plan now has three stages.
<ul>
<li><strong>Rescue</strong> - Do the minimum to get her running safely, pure mechanical rescue, no cosmetic action.</li>
<li><strong>Ride</strong> - Ride her for a bit, identify mechanical issues that need addressing during the rebuild and decide what type of bike I want her to be, Classic, Bobber, Bagger, Caf?®, something else?</li>
<li><strong>Rebuild</strong> – Commit to a “Frame-up Rebuild” plan I am comfortable with, strip her down and get going.</li>
</ul>

 

[kentuvman]

Welcome to the forum.

Quite a project!

I like the pearl white Beemer photo.

Like you, I bought my first Airhead in 2009, a very neglected '82 R65LS. Should've taken my dad's advice - he used to say "take off the radiator cap and put a new car beneath it."

Mine needed EVERYTHING. Only had 19k on the clock but due to age and being stored outside, I elected to replace pushrod seals, rings (as long as i was in engine), and had valve job. Also replaced alternator brushes. Oh, transmission had to be rebuilt too - had a broken 50 cent clip.

Bought a lot of parts from Motobins in England - they have just about an Airhead part you'll need and they're quite efficient and accurate. I find navigating their website easy. Shocks & tires I bought here in US.

Had to re-line tank (POR) as bike had sat outdoors with gas in locked tank (had to drill out lock to remove cap). Carbs needed rebuilding - bought kit from Bing. Had to do again because my first technique didn't remove all the residue - an ultrasonic machine from Harbor Freight did the magic. Removed wiring harness from frame & had it sandblasted & painted and same with black engine parts where paint was all worn off - used soda blaster (also from Harbor Freight) & POR High Heat Paint.

I took similar approach - R&R what needed to be done, put her back together and ride her. It's taken @ 750 miles to work bugs out - exhaust pipe kept blowing out of header - long story. Just a lot of misc. tweaking and tinkering.

Now have her where she almost should be. Runs good and is a lot of fun

Looking forward to watching your posts as you progress with your restoration.

Advice: Be patient. Respect the marvels of engineering. There is a reason every part goes where it goes on your bike. I've learned to take nothing for granted.

 

[themadp]

Advice: Be patient. Respect the marvels of engineering. There is a reason every part goes where it goes on your bike. I've learned to take nothing for granted.

Thanks for the story and advice, looks like I am missing a lot of small bits that could add up to big $ so already off to a good start.. perhaps I should take your dads advice

 

[melville]

I will admit to being a little intimidated by this next project, its my first BMW and my first restoration.

Famous last words

Ooh! Ooh! Ooh! You're gonna play too. Here's mine, first BMW, first restoration, first motorbike:

Link to: Idiot v. R75.

Best of luck!

 

[Na Cl K9]

thoughts

Taking on the task of resurrecting a airhead BMW is an adventure in itself. When you are finished, you can ride it anywhere secure in the knowledge that you can fix just about anything that requires attention along the way. Regardless of what you have been told about BMW's, they still do break and a few parts wear out. I think you would be better off being a bit more pragmatic about the bike. You can buy a running 77 R100/7 complete for 2500.00-3500.00 and that should be something of a benchmark as an estimate of expense.

The bike I see in your photo will probably cost more than that to repair. The bike you have appears to be a /6 and has some components common to 1975 - 76 machines. The transmission is a late /6 - early /7 unit as evidenced by the horizontal casting line across the mid-section of the case. The blue paint (what is left of it anyway) is common to 74 - 76. The shock covers with the three rings is a hold over from 75. I see bar backs and windshield mounts. The seat is remarkable in that the original BMW emblem in white ink/paint is still visible. I doubt the seat is original to the bike itself. The wheels have typically rusty spokes but the rims should be good to go. The front hydraulic brake system is probably FUBAR from sitting but the parts are available. The gas tank if not full of pin holes along the bottom seam should be salvageable.

Does the engine turn over? Can you shift the gears up and down while turning the rear wheel. If so then your rolling parts bin has some intrinsic value and potential. There are lots more questions to ask but your going to be answering them as you go anyway. Now, I always like to know how much you paid for the bike. If it was 500 or less, you have room to make some choices regarding restoration or customization. If you paid more than 1000 for that bike, I would think that you may not be able to economically "restore" that machine which means it is potentially more of a 'builder' than anything. The mileage should be considered to be suspect and various wear points should be considered to ascertain the amount of use its gotten over-all in its life remembering of course that the lions share of "use" has come from sitting all those years. That is the worst kind of abuse. I am starting "B126" this winter. B127 is parked next to it and B128 is out in the storage shed. I still have 'B1' and I remember when I took it apart (the first time) and wondered aloud if it was ever going back together again...good luck to you. Hope your dream bike materializes~ Paul

 

[themadp]

Cataloging the missing pieces

When I purchased the bike I knew there were some bits missing but it looked like it was little stuff.. novice mistake number one! Sat down over the weekend and started to catalog the obviously missing pieces using <a href="http://ascycles.com" target="_blank">ascycles.com</a>.

To my horror the running total quickly soared above $700! I know the PO had two airheads, rebuilt the first one, ran out of time/interest to do this one. I now suspect he pinched parts from this one to get his bike on the road cheaply kicking to cost on to me.

The big things are - New lock set (ignition lock missing, no keys for seat or steering locks), Both throttle cables, Clutch cable, Complete choke setup, Everything attaching the carbs to the engine and air box, Headlamp lens, Karcoma fuel tap.

I'm also missing a bunch of nuts and bolts. Good example is the bolts to hold the top engine cover in place.. 2x Fillister-head screw + washer = $6.64 + tax and shipping.. thatÔÇÖs just 2 bolts!

Talked to 2 salvage yards that say they donÔÇÖt save/have cables and rubber parts as they degrade too fast. e-bay has some of it but factor in P&P and thereÔÇÖs not much saving over new on most of this to my surprise.

From my last build (Ducati) I know nuts and bolts, washers etc. when purchased OEM will get expensive. I have seen these complete stainless steel nut/bolt replacement kits but think thatÔÇÖs overkill.. opinions?

Any advice on buying and using non-OEM nuts, bolts, hose clamps etc.

 

[themadp]

Ooh! Ooh! Ooh! You're gonna play too.

Going to read your thread carefully as it looks like you are way ahead of me.. definitely going to have some "how did you do that" questions for you down the road.

 

[themadp]

Does the engine turn over? Can you shift the gears up and down while turning the rear wheel. If so then your rolling parts bin has some intrinsic value and potential.

Yes, gears shift, engine turns over tank is watertight with very light rust inside.

Now, I always like to know how much you paid for the bike. If it was 500 or less, you have room to make some choices regarding restoration or customization. If you paid more than 1000 for that bike, I would think that you may not be able to economically "restore" that machine which means it is potentially more of a 'builder' than anything.

$1200.. too much by the sounds of it

I am starting "B126" this winter. B127 is parked next to it and B128 is out in the storage shed. I still have 'B1' and I remember when I took it apart (the first time) and wondered aloud if it was ever going back together again...good luck to you. Hope your dream bike materializes~ Paul

Thanks for all the info on the bike as it appears, looks like I have an uphill battle ahead of me.

 

[88bmwjeff]

The big things are - New lock set (ignition lock missing, no keys for seat or steering locks), Both throttle cables, Clutch cable, Complete choke setup, Everything attaching the carbs to the engine and air box, Headlamp lens, Karcoma fuel tap.

Talked to 2 salvage yards that say they donÔÇÖt save/have cables and rubber parts as they degrade too fast. e-bay has some of it but factor in P&P and thereÔÇÖs not much saving over new on most of this to my surprise.

Cables, rubber parts can still be had new from BMW, and I wouldn't consider putting anything but new on the bike. It may seem costly, but better in the long run. Check ebay as part come up frequently, and look at parts lots, since they might contain the parts you're looking for. The headlamp lens you might have to spring for new. Check places like Hucky's (I think I spelled it right). I've read good things about them. There are other avenues, which I'm sure people will speak up about.

 

[abncavscout]

'85 (?) GS bobber !!!

<img class="aligncenter size-full wp-image-317" title="BMW Airhead Bobber" src="http://aprioriworkshop.com/wp-content/uploads/2011/09/e88b12ns6.png" alt="" width="600" height="400" />​

... I almost bought this BMW bobber in the fall of 2007. It was up for sale on eBay and I tried to snipe it for $8,000.01. Unfortunately for me, the previous high bidder had bid a higher amount, and eBay automatically counter-bid for him the minimum increment over my bid. I think he won it for $8,100.01. After that, I decided to raise my snipe to $8,500.01 and the next BMW to come up on eBay that caught my eye was a 2003 BMW R1150GS Adventure with factory headlight guard, factory driving lights, and both the stock, and factory low seats. It also had only 6,552 miles on the odometer. I won it, and have ridden it about 1,600 miles every month since I returned from the mid-east and retired from the Army in February 2009. In the end I love my '03 Adventure, but I will always lust for that '85 (?) GS bobber !!!

Rodger Williamson II
VP, BMWMOAL

 

[kentuvman]

Not so sure I'd worry about the initial cost of the bike.

For me, I've made some great new friends from MOA. I paid $800 for my neglected R65LS with a broken tranny and a bunch of missing parts.

But as I went down the resto process, I approached it like the projects I get in my advertising business - different client requests and juggling many projects simultaneously.

I bought mine in February in Minnesota on a cold winter day. It wasn't until the spring that I realized the bike needed A LOT more than I thought. But I made a project out of it. That's whats fun for me. I enjoy bringing neglected mechanical things back to service - did it with a sailboat, a John Deere 112 tractor, a Honda 125, and an Airstream.

With my bike, there's a specific forum BMWR65.org for my model. Met some great folks. From this forum learned about Mikes Airhead Salvage - he provided me with a missing brake pedal, airbox and some other missing parts. Contacted Matt Parkhouse and shipped my transmission to his shop in Colorado and he did a terrific job overhauling it - I totally trust Matt. Got to interact with the guy at the machine shop who did the valve job. Still have fun ordering parts from local BMW dealer and Motobins. Got to ask about which tires guys liked on their R65's and shock options.

A MOA member, Neil Peterson, a retired mechanical engineer sent me a PM and offered to help me with the project. I wasn't planning on stripping the bike apart but that's what Neil suggested I do. We went through everything new rings, valves, pushrod seals, carb overhaul (as I previously posted). It was a great learning process as I went down the line. Today Neil and I have become good friends.

The compartments or buckets of my project were divided into Engine, Frame, Transmission, Wheels, Shocks, Tires, Electrical components - this helped me make it a manageable project. I had a bike to ride so I wasn't in a big rush.

When I couldn't get the bike to run, a fellow MOA member suggested Judson Cycle in Lake Crystal, MN. I got to meet Ron and his crew. They got the bike running for me.
Got to drive down a few times to see the progress being made and learned about being patient (I was impatient to get bike but held back the horses).

Got bike - had shakeout issues - exhaust pipe blowing off, stripped threads on one of the heads (PO pinned a threaded sleeve there). Paul Glaves suggested how to resolve exhaust blowing off (pipe expansion tool); another MOA suggested exhaust gaskets: Problem Solved. Found a head on Ebay; someone from the R65 forum sold me a new coil (mine had the gray crack-o-matic).

The point for me: this has been a wonderful experience. I got to make friends, I've learned how to work on the bike; I can balance the carbs, time it, diagnosis electrical problems - things I never would have figured out on my own.

When I add up the dollars invested and weigh it against the friends I've made, there's no comparison. I had a good foundation to work with and from what I see of the blue BMW, it has a good foundation too.

I guess there is one more thing to say: I am proud to see my bike restored, up and running,and the confidence to ride it just about anywhere.

There's something special about Airheads! I say, press on - we're here for you!

 

[criminaldesign]

have fun.

in regards to bolts, clamps and such, Fastenal and NAPA have worked out just fine.

 

[crazydrummerdude]

Looks like fun. I am addicted to resurrecting old BMW POS'.

Where are you located?

 

[pandry1]

Electrolysis Rust Removal

Check out rust removal process #E at this website:

http://www.motorcycleanchor.com/motorcycle/how_to/mc_tankrust.html

I used this process on my 1974 R75/6 restoration - been riding all summer with no problems. It's cheap, easy and works well enough.

Also - check out Dunlop tires @ $60.00 - they work great at half the price of Metzlers and others - I can't tell the difference in performance - and I've gone through many sets of Metzlers on my other bikes.

Having just restored this bike (resurrected from 30 years of storage by the ocean in Florida), I have found many inexpensive fixes. Contact me via e-mail if you have questions - pandry1@frontier.com

 

[radar41]

R75/6 Rebuild

Boy does that look familiar!


https://www.facebook.com/media/set/?set=a.1246700326072.2036525.1186338436&l=eefc170a6f&type=1

If you need a list of places for parts, many of us can and will be glad to help.

Join the Airheads Beemer Club: http://www.airheads.org/index.php?Technical Tips

Get ready for some serious elbow grease.

Finally: When you press the starter button for the first time and it "roars" to life . . . . . the smile will make it all worth while.

 

[Walking Eagle]

+1 kentuvman

What he said.

Life is too, too, short to worry about pinching pennies on something as rewarding as getting an old bike back on the road. This is a lot of FUN, and -- Pirsig said it best:

The real cycle you're working on is a cycle called 'yourself.' The study of the art of motorcycle maintenance is really a miniature study of the art of rationality itself. Working on a motorcycle, working well, caring, is to become part of a process, to achieve an inner peace of mind. The motorcycle is primarily a mental phenomenon.

I've not been to a psychiatrist in years. No, really.


Walking Eagle

 

[kentuvman]

I'm smiling because my R65LS project is behind me now

I'll probably pick up a Toaster at some point, but it's not gonna be a ground up project like the R65. But now know a lot about what makes these amazing machines tick.

 

[Na Cl K9]

Encouragement...

Lots of experience typing to you here. I would second the suggestion to pick up a "parts lot" from one of the popular eBay'ers. It does help to have a good supply of OEM fasteners at hand. I like to buy 6mm/8mm bolts in bulk in the longest size I'll need and simply cut them down where necessary. Some fasteners will be specific and you'll need to look around. I have never purchased a stainless bolt kit but that is an option with a great finish guaranteed at the end of what ever build you plan. Something to think about anyway.

The dollar figures are kind of a 'threshold' for me. Nice unmolested airheads seem to be rather more scarce these days. I'm thinking there are still a lot of barn-finds out there to be found and even now, there are probably bikes being consigned to the shed as we speak. You mentioned that the PO ran out of steam (money, time, what ever) and I'd say that might be a slight consideration. 1200.00 is probably 1/4 of what you may wind up putting into the bike and that is in consideration of what others have said they spent on restorations over the years I've followed these threads. I am talking "restoration", there are alternatives.

The fact that your engine turns over and the transmission shifts is all good. I've said it before on other occasions ~ these bikes fall apart around the engine...(but they dont fall back together, unfortunately). Meaning the engine will take a lot of abuse/neglect but the rest of the machine, not so. What you can do is make a list of what you have that is good and compare that list to what you see parts-wise on some of the nice cafe bikes out there like you pictured.

Cleaned up and running in the abbreviated format of the cafe gives you the chance to experiment on a light budget and get it going ~ have fun with it and learn. As you progress, you may find parts that will put it back in original form later and for less money than if you had tried to purchase everything right away. There are a lot of parts from early and later bikes that will fit your 76 and that makes it easier. I have spent a number of years gathering parts for a build. I also agree that new parts (rubber especially) is the way to go. No sense replacing junk with more junk. People complain about the cost of a new handlebar switch but they last 20 years~ and are reliable during that period. Some things are really expensive to replace new like alternator parts, headlight rings and instruments and there you'll have to decide how much to spend. There are not a lot of alternatives from after market suppliers to offset the cost but, a lot of things are being rebuilt now.

 

[poorboywilliams]

More encouragement...

The motorcycle is primarily a mental phenomenon.

+1. I bought my airhead ('74 R90/6) about two years ago now, and after 15 years and an assortment of UJMs, I came to realize what I truly love about motorcycling - the "experience". Rebuilding, servicing, tuning, cleaning, AND (most importantly), riding. It's all part of it, and I feel more connected to the R90 than I ever did to the Yamahas, Suzukis, or Hondas. Great bikes all, but they offer something different IMO.

Mine also came to me in need of plenty of work. More than I bargained for, actually. Parts purchases added up quickly - low bars, new cables, brakes line, master cylinder rebuild, fork rebuild, carb rebuild, top end gaskets, PRT seals, battery, tires, shocks, etc, etc, ad infinitum. I'm probably into my bike now for a good bit more than I could realistically ask for it, but honestly, I don't care. My ongoing experience, through this board, local shops/dealers, other bikers I've met, etc. has been worth the premium.

Having said that, two years on and the majority of the work done, the bike has proven to be reliable, fun to ride, and simple to fix. I just did about 800 trouble free miles on it two weeks ago through the finger lakes of New York State, smiling all the way home.

Welcome and have fun!