1983 R100RS Rebuild Project Journal

I will be very interested to hear your opinion of the Race Tech mod. I have a friend with a /5 who did this and said it was the best money he spent restoring that bike, period. I have a K75 I think I would like to do this to.

GREGFEELER said:

I will be very interested to hear your opinion of the Race Tech mod. I have a friend with a /5 who did this and said it was the best money he spent restoring that bike, period. I have a K75 I think I would like to do this to.

Click to expand...

Greg,

I too am looking forward to what difference these make. I have the stock damper rod in my '77 RS so I can compare the two suspension systems. I suspect I will get to tweak the compression damping setting and the fork spring preload spacer as some adjustment maybe required.

Best.
Brook.

My late brother, who was very picky about how his bikes handled, used to rave about the Emulators...

...in his '78 GoldWing.

He would ride that thing so hard that you could actually see the frame flexing in the corners.

brook.reams said:

Greg,

I too am looking forward to what difference these make. I have the stock damper rod in my '77 RS so I can compare the two suspension systems. I suspect I will get to tweak the compression damping setting and the fork spring preload spacer as some adjustment maybe required.

Best.
Brook.

Click to expand...

I've read all the information on the Race Tech web site about the differences in operation between dampener rod forks, cartridge forks, and the cartridge emulators, and from that info it seems that the cartridge design can provide velocity sensitive dampening that dampener rod forks just can't. However, I was talking today with a good friend of mine who is a highly respected custom BMW bike builder and restorer who said he thought you can get about the same amount of improvement with the stock fork design by making changes in springs, fork oil, and other tweaks. He throught the Race Tech emulators did work, but he just questioned the cost vs. the improvement. I suspect he's correct, but also it could be that most people can get there easier with the cartridge emulators than by doing their own mods to the stock forks given the knowledge and skills that would take. Again, the proof is in the pudding, so I will be awaiting your assessment once you have this bike back on the road.

GREGFEELER said:

He throught the Race Tech emulators did work, but he just questioned the cost vs. the improvement. I suspect he's correct, but also it could be that most people can get there easier with the cartridge emulators than by doing their own mods to the stock forks given the knowledge and skills that would take.

Click to expand...

As has been recently proven more than once, a person can cut their own hair and it is less expensive than the barber. In fact some guys do it often enough the results almost seem barber like. But still, one has to ask is the trial and error and the effort worth the savings? Or not?

I am the definition of a hack mechanic, but at the recommendation of my friends at Max BMW I did the exact same thing on my /5 forks this winter. I left the Race Tech emulator settings as-delivered and followed the instructions exactly for the emulator and springs. It's made a terrific difference, the bike is so much more enjoyable to ride now. I'm a big believer, and expect you'll be pleased as well.

PGlaves said:

As has been recently proven more than once, a person can cut their own hair and it is less expensive than the barber. In fact some guys do it often enough the results almost seem barber like. But still, one has to ask is the trial and error and the effort worth the savings? Or not?

Click to expand...

Exactly. Pay money instead of time but get the results you are looking for. Suspension tuning is not something a lot of people I've met have the talent for.

1983 R100RS/RT Install Toaster Tan Top Brace and Install & Align Front Forks

I decided to upgrade the fork top plate to a Toaster Tan fork top brace as I think it makes a sizable improvement in keeping the forks rigid and improves handling.

<a title="Toaster Tan Top Brace with Fork Tube Rings and Separate Steering Stem Cap Nut" href="https://www.flickr.com/photos/brook-reams/49924841311/in/album-72157714417244603/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49924841311_b250197057_c.jpg" alt="Toaster Tan Top Brace with Fork Tube Rings and Separate Steering Stem Cap Nut" width="800" height="600" /></a>
Toaster Tan Top Brace with Fork Tube Rings and Separate Steering Stem Cap Nut

Installing the fork top brace is part of the procedure for installing and aligning the front forks, so did all of this work at one time. But, I broke up the documentation into two parts covering the Toaster Tan fork top brace and the front fork installation and alignment.
<ul class="children">
<li class="page_item page-item-8324"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/31-bmw-1983-r100rs-rt-install-toaster-tan-top-fork-brace/">31 BMW 1983 R100RS/RT Install Toaster Tan Top Fork Brace</a></li>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/31-bmw-1983-r100rs-rt-install-and-align-front-forks/">31 BMW 1983 R100RS/RT Install and Align Front Forks</a></li>
</ul>
I also made two videos summarizing the procedures.

<strong>VIDEO: <em><span style="text-decoration: underline;">1983 BMW R100RS Install Toaster Tan Fork Top Brace</span></em></strong>

<strong>VIDEO: <em><span style="text-decoration: underline;">1983 BMW R100RS/RT Install and Align Front Forks</span></em></strong>

Here is the finished product.

<a title="Toaster Tan Fork Top Brace & Forks Installed" href="https://www.flickr.com/photos/brook-reams/49939393067/in/album-72157714428391816/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49939393067_c19a30af6d_c.jpg" alt="Toaster Tan Fork Top Brace & Forks Installed" width="800" height="600" /></a>
Toaster Tan Fork Top Brace & Forks Installed

<a title="Forks & Toaster Tan Top Brace Installed" href="https://www.flickr.com/photos/brook-reams/49939443442/in/album-72157714428391816/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49939443442_8ec877b044_c.jpg" alt="Forks & Toaster Tan Top Brace Installed" width="800" height="600" /></a>
Forks & Toaster Tan Top Brace Installed

First two things

First two things I did to my two airheads was to get rid of the stamped upper triple plates. I think I got mine from San Jose. Second, I installed good front fender fork braces also from San Jose. These two things made a noticeable change in handling and were well worth the money. St.

1983 R100RS Install Swing Arm and Rear Drive

Previously, I replaced the swing arm bearings and you can read about how I did that here:
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/33-bmw-1983-r100rs-remove-swing-arm-bearings/">33 BMW 1983 R100RS Remove Swing Arm Bearings</a></li>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/33-bmw-1983-r100rs-install-swing-arm-bearings/">33 BMW 1983 R100RS Install Swing Arm Bearings</a></li>
</ul>
Now I install the swing arm in the frame and then install the rear drive on the end of the drive shaft side of the swing arm. I show how I align the swing arm in the frame to reduce stress on the drive shaft when I install it. The rear drive mounts easily to the flange on the right side of the swing arm with four 12-sided nuts.

Here is a link to the procedure:
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/33-bmw-1983-r100rs-install-swing-arm-and-rear-drive/">33 BMW 1983 R100RS Install Swing Arm and Rear Drive</a></li>
</ul>
And here is a video summarizing how I did the work.


<strong>VIDEO: <span style="text-decoration: underline;"><em>1983 BMW R100RS Install Swing Arm & Rear Drive</em></span></strong>

I had the swing arm powder coated and cleaned up and I refinished the rear drive that had been sprayed black with rattle can paint.

<a title="Rear Swing Arm Removed" href="https://www.flickr.com/photos/brook-reams/46865822204/in/album-72157679833426098/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/7831/46865822204_5dda129d0f_c.jpg" alt="Rear Swing Arm Removed" width="800" height="600" /></a>
Rear Swing Arm Removed

<a title="Powder Coated Swing Arm" href="https://www.flickr.com/photos/brook-reams/49670080251/in/album-72157713519841331/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49670080251_db4cae8a4b_c.jpg" alt="Powder Coated Swing Arm" width="800" height="600" /></a>
Powder Coated Swing Arm

<a title="Right, Rear Drive, Top" href="https://www.flickr.com/photos/brook-reams/16495849025/in/album-72157713502240312/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/7407/16495849025_45a7e9d3cd_c.jpg" alt="Right, Rear Drive, Top" width="800" height="600" /></a>
Right, Rear Drive, Top

<a title="Right, Rear Drive, Rear" href="https://www.flickr.com/photos/brook-reams/16309916917/in/album-72157713502240312/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/7319/16309916917_8fbe05c810_c.jpg" alt="Right, Rear Drive, Rear" width="600" height="800" /></a>
Right, Rear Drive, Rear

<a title="Refinished Rear Drive" href="https://www.flickr.com/photos/brook-reams/49664698547/in/album-72157713502240312/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49664698547_97bdbbaba6_c.jpg" alt="Refinished Rear Drive" width="800" height="600" /></a>
Refinished Rear Drive

<a title="Refinished Rear Drive" href="https://www.flickr.com/photos/brook-reams/49663874883/in/album-72157713502240312/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49663874883_caab5647b3_c.jpg" alt="Refinished Rear Drive" width="800" height="600" /></a>
Refinished Rear Drive

Here is the final product.

<a title="Rear Drive Installed" href="https://www.flickr.com/photos/brook-reams/49957400172/in/album-72157714528951692/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49957400172_9d0335bd6a_c.jpg" alt="Swing Arm And Rear Drive Installed" width="800" height="600" /></a>
Swing Arm And Rear Drive Installed

Dangerous Things Here

Gee whiz Brook, I look at my R80RT with its 200K plus miles on it and think this winter I am going to do a restore on it not to make a show bike but to make it look better.

Your starting pictures are horror shows compared to what my bike looks like. I give you a lot of credit for taking a really filthy, clapped out bike and turning it into a useful beauty again. Not only an outward beauty but an inner beauty as well.

Lots of blokes make things look pretty on the outside hiding lots of sins. I found this out with my R100RS and I am paying for it. It is a pretty bike but I am finding a few sins such as worn jugs and messed up alternator.

Mind you, I have never let my R80RT look like your before pictures, I try very hard to keep the old girl looking good. I am not one to let any mechanical thing go unfixed or ignored. So I am in better shape starting a rebuild with my bike versus this one you are working on now. Your thread has me tilting toward restore.

It is dangerous for me to be following this tread because I might break down and open my wallet and do a restoration on the RT thus exposing me to wrath of the Wife. Just joking, she is good with it.

Cheery bye, St.

STEVENRANKIN said:

Gee whiz Brook, I look at my R80RT with its 200K plus miles on it and think this winter I am going to do a restore on it not to make a show bike but to make it look better.

Your starting pictures are horror shows compared to what my bike looks like. I give you a lot of credit for taking a really filthy, clapped out bike and turning it into a useful beauty again. Not only an outward beauty but an inner beauty as well.

Lots of blokes make things look pretty on the outside hiding lots of sins. I found this out with my R100RS and I am paying for it. It is a pretty bike but I am finding a few sins such as worn jugs and messed up alternator.

Mind you, I have never let my R80RT look like your before pictures, I try very hard to keep the old girl looking good. I am not one to let any mechanical thing go unfixed or ignored. So I am in better shape starting a rebuild with my bike versus this one you are working on now. Your thread has me tilting toward restore.

It is dangerous for me to be following this tread because I might break down and open my wallet and do a restoration on the RT thus exposing me to wrath of the Wife. Just joking, she is good with it.

Cheery bye, St.

Click to expand...

Steve,

Thank you. BTW, anytime I can help someone with a serious addiction (rebuilding airheads) stay addicted, I've done my job

Along the lines of refinishing parts as I do a rebuild, I put a page together that shows how I refinished and repaired parts on this project and update it as I go along. This is not difficult work and frequently does not require special tools, but it often require patience and elbow grease.

• 51 BMW 1983 R100RS Repair, Refinish, Paint

Stay well.

Best.
Brook.

1983 R100RS/RT Assembly From The Frame Up & Other Documentation

I put together a page showing the order in which I am assembling the bike on this project. I will add to it as I go. In most of this document I link to other pages I posted, but for some work that is not particularly detailed, I show how to do the work in the Assembly page.
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/00-bmw-r100rs-rt-assembly-from-the-frame-up/">00 BMW R100RS/RT Assembly From The Frame Up</a></li>
</ul>There is also a companion document that shows how I disassembled the bike.
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/00-bmw-1983-r100rs-disassembly/">00 BMW 1983 R100RS Disassembly Down To The Frame</a></li>
</ul>I also have documented the project work on a Project Index page that includes a list of every document I published for this project organized by parts fiche major component number.
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/">1983 BMW R100RS->RT Build: Project Index</a></li>
</ul>Here is a link to the YouTube videos I've posted about this project on my channel.
<ul>
<li><strong>VIDEOS</strong>: <a href="https://www.youtube.com/playlist?list=PLOMI8_0YotYIVt7h0V8U9uWyN8JKuCS-p" target="_blank" rel="noopener noreferrer">1983 BMW R100RS/RT Rebuild</a></li>
</ul>Lastly, there is a complete archive of all the pictures on Flickr.
<ul>
<li><strong>Flickr Pictures</strong>: <a id="yui_3_11_0_3_1591205647262_400" class="Colla" title="1983 BMW R100RS Into RT Project" href="https://www.flickr.com/photos/brook-reams/collections/72157648419121394/">1983 BMW R100RS Into RT<wbr /> Project</a></li>
</ul>
 

I hope this information is helpful to anyone doing a large scale build, rebuild or restore project.

Great stuff, Brook, as always. I'd be nervous about selecting aluminum cleaners, but the aircraft stuff would be safe, and I assume there is info on Snowbum's site. Jim Von Baden used some Meguiar products on his R1100RS restoration.

BTW, "Solo Bolo" has referenced your build in his lengthy RS restoration report in ADVrider. He ran into a number of very interesting problems.

1983 R100RS Install Sub-Frame, Gazi Shocks, Wheels

I completed installing the rear end of the motorcycle. The fenders and rear lights will come in another post. You can read about how I did that work in these chapters of the "Assembly From The Frame Up" document:
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/00-bmw-r100rs-rt-assembly-from-the-frame-up/">00 BMW 1983 R100RS/RT Assembly From The Frame Up</a>
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/00-bmw-r100rs-rt-assembly-from-the-frame-up/#Install_Sub-Frame">Install Sub-Frame</a></li>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/00-bmw-r100rs-rt-assembly-from-the-frame-up/#Install_New_Gazi_Rear_Shocks">Install New Gazi Rear Shocks</a></li>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/00-bmw-r100rs-rt-assembly-from-the-frame-up/#Install_Wheels">Install Wheels</a></li>
</ul></li></ul>
<a title="Rear Shocks Mounted" href="https://www.flickr.com/photos/brook-reams/49960827476/in/album-72157714541667057/" target="_blank" rel="noopener" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49960827476_5a359e6144_c.jpg" alt="Sub-Frame and Rear Shocks Mounted " width="800" height="600" /></a>
Sub-Frame and Rear Shocks Mounted

<a title="Wheels Installed" href="https://www.flickr.com/photos/brook-reams/49961036621/in/album-72157713880054883/" target="_blank" rel="noopener" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49961036621_553962913c_c.jpg" alt="Wheels Installed" width="800" height="600" /></a>
Wheels Installed

It's beginning to look like a motorcycle again.

Rinty said:

Great stuff, Brook, as always. I'd be nervous about selecting aluminum cleaners, but the aircraft stuff would be safe, and I assume there is info on Snowbum's site. Jim Von Baden used some Meguiar products on his R1100RS restoration.

BTW, "Solo Bolo" has referenced your build in his lengthy RS restoration report in ADVrider. He ran into a number of very interesting problems.

Click to expand...

Hi Rinty,

I've had good success with all the AutoSol products every since my first rebuild project in circa 2009. And, they are a German company

Best.
Brook.

1983 R100RS Install Fork and Seat Locks

I completed installation of the fork and seat locks. I show the assembly of the seat latch mechanism and installation and also made a short video showing how I do the work.
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/51-bmw-1983-r100rs-install-fork-and-seat-locks/">51 BMW 1983 R100RS Install Fork and Seat Locks</a></li>
</ul>

<strong>VIDEO: <em><span style="text-decoration: underline;">1983 BMW R100RS Install Fork and Seat Locks</span></em></strong>

Here is a link showing how I removed the locks.
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/51-bmw-1983-r100rs-remove-fork-seat-locks/">51 BMW 1983 R100RS Remove Fork & Seat Locks</a></li>
</ul>

1983 R100RS/RT Routing The Main Wiring Harness

I show how I route the main wiring harness after I installed the headlight shell. Previously I replaced the main harness with one from Euro MotoElectrics.
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/61-bmw-1983-bmw-r100rs-rt-replace-main-wiring-harness/">61 BMW 1983 BMW R100RS/RT Replace Main Wiring Harness</a></li>
</ul>
Here is the document showing the details and a short video.
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/61-bmw-1983-r100rs-rt-routing-main-wiring-harness/">61 BMW 1983 R100RS/RT Routing Main Wiring Harness</a></li>
</ul>

<strong>VIDEO: <em>1983 BMW R100RS Routing Main Wiring Harness</em></strong>

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

<a title="Main Harness Exits Bottom Of Headlight Shell" href="https://www.flickr.com/photos/brook-reams/50006929117/in/album-72157714710293853/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/50006929117_3ebe757abc_c.jpg" alt="Main Harness Cable Exits Bottom Of Headlight Shell" width="800" height="405" /></a>
Main Harness Cable Exits Bottom Of Headlight Shell

<a title="Main Harness Goes Under Lower Triple Clamp (aka Yoke)" href="https://www.flickr.com/photos/brook-reams/50006928997/in/album-72157714710293853/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/50006928997_5caf1d9c0a_c.jpg" alt="Main Harness Goes Under Lower Triple Clamp (aka Yoke)" width="800" height="450" /></a>
Main Harness Goes Under Lower Triple Clamp (aka Yoke)

<a title="Main Harness Goes Between Frame Down Tubes" href="https://www.flickr.com/photos/brook-reams/50006143918/in/album-72157714710293853/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/50006143918_9e322cb6ee_c.jpg" alt="Main Harness Goes Between Frame Down Tubes" width="800" height="450" /></a>
Main Harness Goes Between Frame Down Tubes

<a title="Main Harness Goes Between Spine Tube and Reinforcing Tube" href="https://www.flickr.com/photos/brook-reams/50006143893/in/album-72157714710293853/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/50006143893_3c66c0f4bd_c.jpg" alt="Main Harness Goes Between Spine Tube and Reinforcing Tube" width="800" height="450" /></a>
Main Harness Goes Between Spine Tube and Reinforcing Tube

<a title="Front Brake Light Switch Sub-Harness Plug (GREEN-Red, GREEN-Black) & Clutch Switch Sub-Harness Plug (BROWN-Yellow)" href="https://www.flickr.com/photos/brook-reams/50006674196/in/album-72157714710293853/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/50006674196_657e497693_c.jpg" alt="Front Brake Light Switch Sub-Harness Plug (GREEN-Red, GREEN-Black) & Clutch Switch Sub-Harness Plug (BROWN-Yellow)" width="800" height="532" /></a>
Front Brake Light Switch Sub-Harness Plug (<strong><span style="color: #00ff00;">GREEN</span>-<span style="color: #ff0000;">Red</span></strong>, <strong><span style="color: #00ff00;">GREEN</span>-Black</strong>) & Clutch Switch Sub-Harness Plug (<strong><span style="color: #993300;">BROWN</span>-<span style="color: #ffcc00;">Yellow</span></strong> and <span style="color: #993300;"><strong>BROWN</strong> </span>)

<a title="Main Wiring Harness Coil Power Terminal (GREEN-Blue) Goes On Same Terminal As EME Optical-Electronic Ignition Control Unit Power Wire (RED)" href="https://www.flickr.com/photos/brook-reams/50016745128/in/album-72157714710293853/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/50016745128_c0a29dc343_c.jpg" alt="Main Wiring Harness Coil Power Terminal (GREEN-Blue) Goes On Same Terminal As EME Optical-Electronic Ignition Control Unit Power Wire (RED)" width="800" height="532" /></a>
Main Wiring Harness Coil Power Terminal (<strong><span style="color: #00ff00;">GREEN</span>-<span style="color: #0000ff;">Blue</span></strong>) Goes On Same Terminal As EME Optical-Electronic Ignition Control Unit Power Wire (<span style="color: #ff0000;"><strong>RED</strong></span>)

Now you post pictures

Okay Brook, why didn't you do this restore 10 years ago? LOL. I had a R90S I had been restoring on my lift for five years. The last thing I had to do was run the main wire harness and other wiring. That was the straw that broke the camel's back. Glenn at the Beemer Barn now has the bike.

No, I lie, I just had major medical issues and couldn't finish it. But, I did some head scratching as to how the main harness was installed at the time.

Thanks for the update and pictures. Great Job, St.

You've got the whole thing memorized!