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Thread: 1983 R100RS Rebuild Project Journal

  1. #91
    Registered User STEVENRANKIN's Avatar
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    Looking Good

    It is looking good Brook, fun watching the progress. St.

  2. #92
    B Reams brook.reams's Avatar
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    Quote Originally Posted by STEVENRANKIN View Post
    It is looking good Brook, fun watching the progress. St.
    Thanks Steve. If I don't look at the stack of uninstalled parts, I too think I'm getting there. The big turning point for me is when I install the engine into the frame. For some reason, that milestone always makes me feel like I'm on the home stretch.

    Best.
    Brook.
    Brook Reams - Arvada, CO
    Endeavor to Persevere
    Various Two-wheeled Vices, All BMW || Website: Airhead Rebuild Projects
    2004 R1150-RS||2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  3. #93
    Registered User STEVENRANKIN's Avatar
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    musings

    Hey Brook, the last bike I restored was fine until I got to the wiring harnesses. It was then I drew a big blank.

    Took awhile to figure out how things were routed. Went from a bundle of snakes to a proper job. LOL. St.

  4. #94
    Registered User Rinty's Avatar
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    Quote Originally Posted by brook.reams View Post
    Hi Rinty,



    But, you can see what I did do below...I think this adds new meaning to "belt and suspenders" and maybe more like "belt, suspenders and velcro"
    Pretty elegant, actually. And I see you dealt with the ground wires in your video....

    That kit is so nice it makes me want to get another RS just so I can install one in it. I wonder where Rick gets all that stuff manufactured.

    Do you think there's any risk that water might get in around the edges of that "two hole" grommet above the diode board?
    Last edited by Rinty; 02-10-2020 at 02:01 AM.
    Rinty

  5. #95
    B Reams brook.reams's Avatar
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    Quote Originally Posted by Rinty View Post
    Pretty elegant, actually. And I see you dealt with the ground wires in your video....

    That kit is so nice it makes me want to get another RS just so I can install one in it. I wonder where Rick gets all that stuff manufactured.
    Rinty, I think you are confusing Euro MotoElectrics, where I got this charging kit, operated by Norman Schawb, with Motorad Electrik, operated by Rick Jones. I believe Norman mentioned this is made in Germany.

    Best.
    Brook.
    Brook Reams - Arvada, CO
    Endeavor to Persevere
    Various Two-wheeled Vices, All BMW || Website: Airhead Rebuild Projects
    2004 R1150-RS||2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  6. #96
    Registered User Rinty's Avatar
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    Quote Originally Posted by brook.reams View Post
    Rinty, I think you are confusing Euro MotoElectrics, where I got this charging kit, operated by Norman Schawb, with Motorad Electrik, operated by Rick Jones...
    I'm confused all over, in this thread...
    Rinty

  7. #97
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    Thumbs up 1983 R100RS Replace Oil Pan & Oil Suction Flange Gaskets, Sand Oil Pan Mating Surface

    Folks,

    It's time to work on the bottom of the engine.

    Engine Block Securely Mounted On Harbor Freight Motorcycle Stand
    Engine Block Securely Mounted On Harbor Freight Motorcycle Stand

    I replaced the oil pan and the oil pump suction flange gaskets.

    New Gaskets-Green Is Oil Pump Suction Flange Gasket
    New Gaskets-Green Is Oil Pump Suction Flange Gasket

    Along the way, I checked the oil pan to see if the mating surface was flat. It was not, so I sanded it and now it's flat. That should go a long way to ensure the new pan gasket does not leak.

    Checking For Uneven Mating Surface On Oil Pan
    Checking For Uneven Mating Surface On Oil Pan

    You can read about how I did the work here:
    And here is a short video summarizing the procedure.


    VIDEO: 1983 BMW R100RS Replace Oil Pan & Oil Suction Flange Gaskets

    The gaskets I need are included in the EMC engine gasket kit. I'm also going to replace the oil pan bolts and wave washers with new stainless steel hardware I got in the bolt kit from "The Bolt Guy" for the RT model since I'm converting the RS to an RT, not that RT pan bolts are different from RS ones.

    To prevent the threads of the stainless steel bolts from galling in the aluminum bolt holes in the engine block, I apply anti-seize. However, it's a lubricant. Since the recommended torque for the bolts is 6 FT-Lbs, which is quite low, if I torque the lubricated stainless steel bolts to that value, I stand a good chance of stripping the threads. So I reduce the torque by 20% to protect the threads.

    For low torque like this, I always use my INCH pound torque wrench, NEVER a FOOT pound wrench which is too inaccurate at that low a torque setting.
    Brook Reams - Arvada, CO
    Endeavor to Persevere
    Various Two-wheeled Vices, All BMW || Website: Airhead Rebuild Projects
    2004 R1150-RS||2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  8. #98
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    1983 R100RS Install The Engine In The Frame

    I always mark the installation of the engine back into the frame as a happy milestone. At last, entropy is being reduced along with the parts pile in the corner.

    Here is a short video showing how I install the engine.



    VIDEO: 1983 BMW R100RS Install The Engine In The Frame

    And some pictures.

    Frame Back From Powder Coating
    Frame Back From Powder Coating

    Frame Rails Protected with Foam Packing Wrap
    Frame Rails Protected with Foam Packing Wrap

    Engine Ready To Pickup And Install
    Engine Ready To Pickup And Install

    Engine Slides Into Frame At The Rear
    Engine Slides Into Frame At The Rear

    Front & Rear Engine Mounting Rods Installed
    Front & Rear Engine Mounting Rods Installed

    Engine & Frame Strapped to Motorcycle Stand
    Engine & Frame Strapped to Motorcycle Stand
    Brook Reams - Arvada, CO
    Endeavor to Persevere
    Various Two-wheeled Vices, All BMW || Website: Airhead Rebuild Projects
    2004 R1150-RS||2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  9. #99
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    1983 R100RS Install Push Rod Tubes and Head Studs

    I decided to install 9.5:1 high compression pistons used in the earlier RS engines instead of the original 8.2:1 pistons used in the 1983 RS motor. Due to variability in piston diameter and the tight clearance required with Nikasil cylinders, the advice of Tom Cutter at Rubber Chicken Racing Garage is to replate the cylinders with Nikasil and hone them so they provide the optimal clearance with the new pistons. So I sent the cylinders and new pistons to him to have this done, but before I did, I removed the push rod tubes and the head studs from the cylinders. You can see how I do that here:
    Now I am ready to install new stainless steel push rod tubes and the original head studs into the cylinders.

    Here is a link to the write-up.
    And a short video summarizing the procedure.

    VIDEO: 1983 BMW R100RS Install Push Rod Tubes & Head Studs
    Brook Reams - Arvada, CO
    Endeavor to Persevere
    Various Two-wheeled Vices, All BMW || Website: Airhead Rebuild Projects
    2004 R1150-RS||2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  10. #100
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    1983 R100RS Install Connecting Rods and Cam Followers

    I had the connecting rods inspected, reconditioned, and new wrist pin bushings installed by Tom Cutter at Rubber Chicken Racing Garage.

    Connecting Rod Parts
    Connecting Rod Parts

    I did that since this engine has over 83,000 miles on it. As Tom said about the life of connecting rods:

    "Metal parts get deformed when they get traumatized by 270 TRILLION
    combustion cycles (4500 RPM, 60 MPH, 100,000 miles= 270 and more zeroes
    than I have left in my computer.) Just a lotta lotta little taps will make
    metal flow. In the case of connecting rods, that becomes manifested in
    misaligned and ovalled bearing bores. Wristpins rock, both radially as well
    as axially, which deforms the small-end bushings. That stuff needs
    attention on a high-mileage engine reconditioning."

    Here is how I install the reconditioned rods and the cam followers.
    And here is a short video summarizing the procedure.



    VIDEO: 1983 R100RS Install Connecting Rods & Cam Followers
    Brook Reams - Arvada, CO
    Endeavor to Persevere
    Various Two-wheeled Vices, All BMW || Website: Airhead Rebuild Projects
    2004 R1150-RS||2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  11. #101
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    1983 R100RS Install Engine Top End

    The engine came with the stock 8.2:1 compression pistons. But the early RS motors came with high compression 9.5:1 pistons. The bike has 83,000+ miles on it. So I decided to install new high compression pistons. Tom Cutter at Rubber Chicken Racing Garage, told me due to the very tight piston clearances in the Nikasil cylinders and the amount of variation in piston diameter with the new pistons, the best way to proceed is to replate the cylinders with Nikasil and hone them to match the pistons to ensure proper clearance. So, I send him the new pistons, rings, wrist pins and old cylinders for this work to be done. I also had him vapor hone the cylinders to refinish them to the factory patina.

    Refinished Cylinders with New Push Rod Tubes
    Refinished Cylinders with New Push Rod Tubes

    The other work needed was to the heads. When I tested them, the valves were leaking. So I sent the heads to Randy Long, at Long's Mechanical Services, who is a well respected head rebuilder, for his opinion. We decided to replace the exhaust valves, all the exhaust guides, springs and keepers. I had him machine the heads for dual plugs. I have dual plug heads on two airhead bikes and I like the improved gas mileage. Randy milled the valve cover mating surfaces so they are flat and bead blasted the heads so they look brand new.

    Randy Long's Rebuilt Heads
    Randy Long's Rebuilt Heads

    Rebuilt Head with New Exhaust Valve and Dual Plug Conversion
    Rebuilt Head with New Exhaust Valve and Dual Plug Conversion (Note Two Spark Plug Holes)

    Here is what I ended up with. The red tape indicates things I need to do before first engine start: install new spark plugs and put oil in the engine. The rags protect the heads from getting anything inside from the intake and exhaust ports.

    Red Tape Means Not Ready Yet
    Red Tape Means Not Ready Yet

    All Done
    All Done

    Here is written documentation of the procedure:
    And here is a video of the procedure.



    VIDEO: 1983 BMW R100RS Install Engine Top End
    Brook Reams - Arvada, CO
    Endeavor to Persevere
    Various Two-wheeled Vices, All BMW || Website: Airhead Rebuild Projects
    2004 R1150-RS||2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  12. #102
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    1983 R100RS Install Drive Shaft & Swing Arm Bearings

    I removed the drive shaft so I can get the swing arm powder coated. You can read about how I removed it here.
    Now that the swing arm is back, it's time to install the drive shaft and new swing arm bearings.

    Powder Coated Swing Arm
    Powder Coated Swing Arm

    I use the Cycle Works drive shaft spring compressor to install the drive shaft by compressing the spring as I did when I removed the drive shaft so I can install the new snap ring that secures all the drive shaft components on the shaft.

    Cycle Works Drive Shaft Spring Compression Tool Components
    Cycle Works Drive Shaft Spring Compression Tool Components

    Drive Shaft Parts
    Drive Shaft Parts
    A-Drive Shaft
    B-Spring Retaining Collar
    C-Spring
    D-Yoke
    E-Bell Coupling
    F-Snap Ring Retaining Collar
    G-Snap Ring

    All Done-Rear Drive End
    All Done-Rear Drive End

    I installed the new sealed swing arm bearings using a large socket. I remove the dust cover and drove the bearings into the swing arm with the socket and a hammer.

    Front Face of Bearing With Dust Seal
    Front Face of Bearing With Dust Seal

    Dust Seal Removed
    Dust Seal Removed

    Front Face Of New Bearing Has A Sleeve
    Front Face Of New Bearing Has A Sleeve

    Driving The Bearing Into The Swing Arm with Just The Socket Was Easier
    Driving The Bearing Into The Swing Arm with Just The Socket Was Easier

    You can read about how I do this work here:

    And here are links to two short videos summarizing how I do the work.

    VIDEO: 1983 BMW R100RS Install Drive Shaft
    https://youtu.be/GvcegHx90Ho

    VIDEO: 1983 BMW R100RS Install Swing Arm Bearings
    https://youtu.be/_RtxM-FY9s4
    Brook Reams - Arvada, CO
    Endeavor to Persevere
    Various Two-wheeled Vices, All BMW || Website: Airhead Rebuild Projects
    2004 R1150-RS||2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  13. #103
    B Reams brook.reams's Avatar
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    1983 R100RS Repair, Refinish, Paint

    I get questions every now and then that are along the lines, "How did you get that so clean ... looking like new ...". So I posted a page that I will keep updating as I go to collect information about how I repair, refinish and paint parts during this project. You can find it here:

    Here are a couple before and after pictures from the work I've done so far.

    BEFORE: Brembo Rear Brake Caliper
    BEFORE: Brembo Rear Brake Caliper

    AFTER: Repainted & Rebuilt
    AFTER: Repainted & Rebuilt[/caption]

    BEFORE: Left Carburetor Top
    BEFORE: Left Carburetor Top[/caption]

    BEFORE: Left Carburetor Choke Side
    BEFORE: Left Carburetor Choke Side

    AFTER: Choke Side of Carburetor
    AFTER: Choke Side of Carburetor

    AFTER: Top Side of Carburetor
    AFTER: Top Side of Carburetor

    BEFORE-Inner Timing Cover
    BEFORE-Inner Timing Cover

    BEFORE-Inner Timing Cover
    BEFORE-Inner Timing Cover

    Finished Inner Timing Cover
    Finished Inner Timing Cover

    Front Engine Cover with Corrosion
    Front Engine Cover with Corrosion

    Refinished Front Engine Cover
    Refinished Front Engine Cover

    Rear Drive Was Painted Black
    Rear Drive Was Painted Black

    Rear Drive Was Painted Black
    Rear Drive Was Painted Black

    Refinished Rear Drive
    Refinished Rear Drive

    Refinished Rear Drive
    Refinished Rear Drive
    Brook Reams - Arvada, CO
    Endeavor to Persevere
    Various Two-wheeled Vices, All BMW || Website: Airhead Rebuild Projects
    2004 R1150-RS||2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  14. #104
    Registered User STEVENRANKIN's Avatar
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    I love it

    I love seeing things re stored to new again.

    I am looking at my 84 R80RT with 200K on it and many years of riding in all kinds of weather debating on spending the summer pulling it apart and doing a rebuild. It needs nothing mechanical just cosmetics.

    I keep up with it but, there are a few dings in the fairing, the pinstripe is worn on the tank, Engine cases and such are not pretty.

    I have my RS to ride while it is apart. Maybe, just maybe it will happen. St.

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