1983 R100RS Rebuild Project Journal

Folks,

As I did on my last project, rebuilding a 1973 R75/5, I'm going to post updates on my new project, rebuilding a 1983 R100RS with 83,382 miles on it.

I just posted the first installment on my blog site, Motorcycles and Other Musings,

• 00 BMW R100RS Pre-Project Inspection

and started the 1983 BMW R100RS Rebuild: Project Index" project index pagewhere you can go for all the links to my procedure write-ups for this project.

Here are a couple pictures from the "home coming" journey.

<a href="https://www.flickr.com/photos/brook-reams/16074788727" title="Hidden in the Back by Brook Reams, on Flickr"><img src="https://farm9.staticflickr.com/8565/16074788727_cd42ec79b5_z.jpg" width="640" height="480" alt="Hidden in the Back"></a>
Hidden in the Back by Brook Reams, on Flickr

<a href="https://www.flickr.com/photos/brook-reams/15638228024" title="Loading by Brook Reams, on Flickr"><img src="https://farm8.staticflickr.com/7532/15638228024_e206b2e334_z.jpg" width="640" height="480" alt="Loading"></a>
ABC Colorado Air Marshal, Dick Paschen Loading the New Project Up by Brook Reams, on Flickr

<a href="https://www.flickr.com/photos/brook-reams/16073114388" title="Extra Parts Included by Brook Reams, on Flickr"><img src="https://farm9.staticflickr.com/8637/16073114388_166501a8f8_z.jpg" width="640" height="480" alt="Extras Included"></a>
Extra Parts Included by Brook Reams, on Flickr

<a href="https://www.flickr.com/photos/brook-reams/15638289594" title="Bike & Bags by Brook Reams, on Flickr"><img src="https://farm8.staticflickr.com/7500/15638289594_bdc4096f6c_z.jpg" width="640" height="480" alt="Bike & Bags"></a>
Bike & Bags at "Brook's Garage" by Brook Reams, on Flickr

<a href="https://www.flickr.com/photos/brook-reams/16308118398" title="Speedmeter & Odometer-83,382 Miles by Brook Reams, on Flickr"><img src="https://farm9.staticflickr.com/8652/16308118398_df0ea1f1f8_z.jpg" width="640" height="480" alt="Speedmeter & Odometer-83,382 Miles"></a>
Speedmeter & Odometer-83,382 Miles by Brook Reams, on Flickr

Oh, boy, sit back and prepare to be amazed!!

20774 said:

Oh, boy, sit back and prepare to be amazed!!

Click to expand...

Kurt,

This could be interpreted in several ways ;-) What's amazzing is the effort you put into moderating this list, helping me with questions and providing great support to the Airhead community. I greatly appreciate your efforts.

Best.
Brook.

Thanks for that...the moderator team tries to keep the "rubber side down" here so we can share our information and thoughts. But having such well documented refurbishments for others to refer to is priceless.

From an Airhead standpoint, we could use more DIY posts (OK, how about some! ) that newbies could refer to when doing regular maintenance. So often I'm 80% done with an oil/filter change before I remember I could have documented it. Then I give myself a dope slap and leave an oil mark on my forehead. But really, more visuals would help all of us.

In 2005 I rebuilt my 82 RS. I look forward to watching this progress and to see what I might have done better. I still have the bike and LOVE it.

Jaguar

Brook,

The left-rear fender in this thread's first pic looks suspiciously like a 3.4 or 3.8 Jaguar sedan. I had an XK-150 once, the the bumper design is familiar.

dbrick said:

Brook,

The left-rear fender in this thread's first pic looks suspiciously like a 3.4 or 3.8 Jaguar sedan. I had an XK-150 once, the the bumper design is familiar.

Click to expand...

Hi Dave,

I think it was a jaguar sedan. The PO is a young mechanic and there were several projects strewn around the farm and in the garage.

Sorry about the late reply, but I was in Europe and then Morocco riding the Atlas mountains on an F700-GS ... I know, sucky duty, but someone has to do it

Best.
Brook.

1983 R100RS Rebuild Project Journal: Bing Type 94 Rebuild/Refinish

You know, being retired just seems to leave no time to work in the shop. I end up doing all sorts of things and the next thing you know, time for bed. Anyway, I finally wrote up the Bing carburetor rebuild/refinish work I did on the 1983 R100RS project.

When I rebuilt a 1973 BMW R75/5, I covered the procedure to rebuild the Bing type 64 carburetors, which are 32 mm, and the Karcoma petcocks. The R100RS has type 94 carburetors that are 40 mm and the Karcoma petcock outlet is 90 degrees from the inlet instead of directly underneath the inlet as for the R75/5. After 10 years, the designs are essentially the same, but there are some differences which I cover in the procedure write-up.

Here is the link to the R100RS Bing type 94 rebuild/refinish procedures.

• 13 BMW R100/RS Rebuild Bing Carburetors & Karcoma Petcocks [Type 94]

I hope this material makes it straight forward for folks to rebuild these carburetors who may have been afraid to tackle a carburetor rebuild. Here are some before and after pictures of the carburetors.

<strong>Before Rebuild/Refinish</strong>

<a title="Left Carburetor Side by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/16495851075"><img src="https://farm8.staticflickr.com/7451/16495851075_b1ff023733_z.jpg" alt="Before-Left Carburetor" width="640" height="480" /></a>
Before-R100RS Type 94 Left Carburetor

<a title="Rusted Top Screws-Soaked in Kroil Overnight by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/16744550989"><img src="https://farm9.staticflickr.com/8728/16744550989_5b6d98711c_z.jpg" alt="" width="640" height="426" /></a>
Rusty Screws and Cap on Dome

<a title="Engine Side of Carburetor by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/16929773801"><img src="https://farm9.staticflickr.com/8709/16929773801_a31d3b8923_z.jpg" alt="Engine Side of Carburetor" width="426" height="640" /></a>
Grunge and Fuel Stains

<a title="Float Bowl Removed by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/16743314600"><img src="https://farm8.staticflickr.com/7605/16743314600_8492ae4bab_z.jpg" alt="Float Bowl Removed" width="426" height="640" /></a>
Float Bowl Removed, Missing Paint on Emblem

<strong>After Rebuild/Refinish</strong>

<a title="Inside of Carburetor by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/16930744135"><img src="https://farm9.staticflickr.com/8688/16930744135_086b85b440_z.jpg" alt="Engine Side of Restored / Rebuilt Carburetor" width="426" height="640" /></a>
Engine Side of Restored / Rebuilt Carburetor

<a title="Top Side of Carburetor by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/16929452862"><img src="https://farm9.staticflickr.com/8698/16929452862_2f49c0b7b2_z.jpg" alt="Top Side of Restored / Rebuilt Carburetor" width="640" height="426" /></a>
Top Side of Restored / Rebuilt Carburetor

<a title="Engine Side of Carburetor by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/16743304390"><img src="https://farm9.staticflickr.com/8709/16743304390_d2b6e3cb69_z.jpg" alt="Outlet Side of of Restored / Rebuilt Carburetor" width="426" height="640" /></a>
Outlet Side of of Restored / Rebuilt Carburetor

<a title="Carburetor Mounted - Clean by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/16723414427"><img src="https://farm9.staticflickr.com/8746/16723414427_1c5ce9b1e6_z.jpg" alt="Carburetor Mounted - Clean" width="640" height="426" /></a>
After-R100RS Type 94 Rebuilt and Refinished Carburetor

They're looking good, Brook. Thanks for the write up.

Rinty said:

They're looking good, Brook. Thanks for the write up.

Click to expand...

You're Welcome Rinty.

Best.
Brook.

brook.reams said:

Hi Dave,

I think it was a jaguar sedan. The PO is a young mechanic and there were several projects strewn around the farm and in the garage.

Sorry about the late reply, but I was in Europe and then Morocco riding the Atlas mountains on an F700-GS ... I know, sucky duty, but someone has to do it

Best.
Brook.

Click to expand...

That's a first-class explanation...wish it had been me!

Rebuild project

20774 said:

Oh, boy, sit back and prepare to be amazed!!

Click to expand...

I look forward to following your progress. Right off, I have two related questions.

1) What kind of windscreen is on the bike? It looks about half the size of the one on my R80RT. It looks like there would be correspondingly less wind resistance.

2) Regarding the carburetor rebuild, I saw that Bing sells an instructional DVD along with its rebuild kits. Does anyone think it's any good / worth the money?

tyro said:

I look forward to following your progress. Right off, I have two related questions.

1) What kind of windscreen is on the bike? It looks about half the size of the one on my R80RT. It looks like there would be correspondingly less wind resistance.

2) Regarding the carburetor rebuild, I saw that Bing sells an instructional DVD along with its rebuild kits. Does anyone think it's any good / worth the money?

Click to expand...

Bing DVD is excellent IMHO

tyro said:

I look forward to following your progress. Right off, I have two related questions.

1) What kind of windscreen is on the bike? It looks about half the size of the one on my R80RT. It looks like there would be correspondingly less wind resistance.

2) Regarding the carburetor rebuild, I saw that Bing sells an instructional DVD along with its rebuild kits. Does anyone think it's any good / worth the money?

Click to expand...

HI Tyro,

It's the stock RS screen AFAIK. Of course, the RT upper faring is different from the RS as it's wider and so the screen will be larger than the one on the RS.

Can't say anything about the Bing DVD. I did buy their manual that explains the operation of the constant velocity carburetors and also provides clues about how the jets interact across the RPM range to help with tuning.

Hope that helps.

Best.
Brook.

This is better than the movies



Thanks for sharing this Brook.

Love your Icon

22600 said:

Thanks for sharing this Brook.

Click to expand...

You're entirely welcome. And, I love the bike and the color in your icon. Very nice.

Best.
Brook.

1983 R100RS Rebuild Project Journal: Replace Choke and Throttle Cables

When I did the inspection of the bike, the throttle and choke cables looked pretty worn with kinks showing in the outer armor. The Bowden connector rubber boots are disintegrating. I’m replacing the cables before riding the bike as I don’t want a stuck throttle or broken cable to happen. I found removing the cables from the Bowden connector required a little technique, but once I figured this out for the choke, the throttle was done pretty quickly.

Here is the procedure I followed:

• 
  32 BMW R100RS Replace Choke and Throttle Cables

Here are a couple before and after pictures.

<a title="Choke Lever Removed from Housing by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/17327319273"><img src="https://c2.staticflickr.com/6/5464/17327319273_94288f4fb1_z.jpg" alt="Choke Lever Removed from Housing" width="640" height="426" /></a>
Choke Lever Removed from Housing (Note Broken Strand in Choke Cable)

<a title="Choke Cables-Long is From Handlebar by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/17761570719"><img src="https://c2.staticflickr.com/6/5452/17761570719_ea5677e8d2_z.jpg" alt="Choke Cables-Long is Handlebar Cable" width="640" height="426" /></a>
Choke Cables-Long One is Handlebar Cable

<a title="Choke Bowden Connector on Left Side by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/17947833645"><img src="https://c2.staticflickr.com/6/5328/17947833645_8fe3d7e050_z.jpg" alt="Choke Bowden Connector on Left Side" width="640" height="426" /></a>
Choke Bowden Connector on Left Side with Disintegrating Rubber Boot

<a title="Assembled Choke Bowden Cable by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/17948501041"><img src="https://c2.staticflickr.com/6/5443/17948501041_9006ec520c_z.jpg" alt="Assembled Choke Bowden Cable" width="640" height="426" /></a>
Finished Choke Bowden Connector with New Cables

I'm completing a front fork rubber cup replacement and check of the fork alignment. I hope to post that soon. After that, I think the bike is ready for my first ride.

1983 R100RS Rebuild Project Journal: BMW Pannier Repair-Cracks, Latch & Lock Numbers

In 1983, the R100RS came with BMW branded panniers, or saddle bags. Mine have a number of cracks and a broken lid hinge. While I'm waiting for some fork parts to come, I started to repair the panniers. My goal was to try and make the crack repairs invisible. I think I got a B+ this time and learned a lot about how to create the textured surface in the plastic on the outside of the pannier.

I've tried <a href="http://www.plast-aid.com/" target="_blank">a plastic repair product, Plast-aid</a>, before to <a href="http://brook.reams.me/2014/07/10/1973-bmw-r755-rebuild-using-plast-aid-to-attach-electric-connector-in-windjammer-fairing/" target="_blank">fix the bulkhead connector on a Windjammer fairing</a>. I'm using it on the panniers. It can be colored using Acrylic paint so the Plast-aid color will match the black panniers. I also fixed a broken latch assembly and learned about locks and keys and how to figure out what key you need for a lock. Here is the link to the write-up on this work.
<ul class="children">
<li class="page_item page-item-3867"><a href="http://brook.reams.me/bmw-motorcyle-rebuilds/1983-bmw-r100rs-rebuild-project-index/46-bmw-r100rs-repair-panniers-plastic/">46 BMW R100RS Repair Panniers & Plastic</a></li></ul>
I discovered that two different keys are not enough for all the pannier locks. Some have been replaced so I have four different locks needing four different keys. I posted a note to the <a href="http://micapeak.com/mailman/listinfo/AIRHEADS" target="_blank">Micapeak Airheads forum</a> about this and learned that the latch locks are no longer available, but, Larry Stonestreet, owner of Stoner's Beemer Stash [ca.stoner@yahoo.com; 951-813-1704] has the keys I need. So all's good. There is a <a href="http://bmwmotorcycletech.info/locks-caps-etc.htm" target="_blank">nice page on Bob Fleischer's site about the locks and keys</a> BMW has used with part numbers of the various keys.

Here are some pictures from the write-up.

<a title="Latch Cracks by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/18036982836"><img src="https://c1.staticflickr.com/9/8893/18036982836_830aa9d5e7_z.jpg" alt="Double Latch Cracks" width="640" height="426" /></a>
Double Latch Cracks

<a title="Corner Cracks by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/18060139742"><img src="https://c2.staticflickr.com/6/5346/18060139742_cfb7e0f264_z.jpg" alt="Mulitple Corner Cracks" width="426" height="640" /></a>
Crushed Corner With Multiple Cracks

<a title="Double Latch Crack Final Repair by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/17987224189"><img src="https://c1.staticflickr.com/9/8829/17987224189_41956265f3_z.jpg" alt="Double Latch Crack Final Repair" width="640" height="426" /></a>
Double Latch Crack Final Repair

]<a title="Crushed Corner Final Repair by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/17987223929"><img src="https://c1.staticflickr.com/9/8848/17987223929_6334e09a80_z.jpg" alt="Crushed Corner Final Repair" width="640" height="426" /></a>
Crushed Corner Final Repair

<a title="Plast-Aid and Black Acrylic Pait by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/17442942943"><img src="https://c1.staticflickr.com/9/8805/17442942943_6077f7928f_z.jpg" alt="Plast-Aid and Black Acrylic Paint for Tinting" width="640" height="426" /></a>
Plast-Aid and Black Acrylic Paint for Tinting

<a title="Dremel Bit for Widening Back of Crack by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/17519213773"><img src="https://c4.staticflickr.com/8/7744/17519213773_2d26eabfc0_z.jpg" alt="Round Dremel Bit for Widening Back of Crack" width="640" height="426" /></a>
Round Dremel Bit for Widening Back of Crack

<a title="Dremel Engraving Tool #106-A Bit Too Big by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/17987224659"><img src="https://c4.staticflickr.com/8/7780/17987224659_18907c149e_z.jpg" alt="Dremel Engraving Tool #106-A Bit Too Big" width="640" height="426" /></a>
Dremel Engraving Tool #106 to Etch Texture Into Plastic-A Bit Too Big, #105 Is Better

<a title="JB Weld Applied to Hinge Plate by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/18060127782"><img src="https://c1.staticflickr.com/9/8898/18060127782_b0cd39c0cc_z.jpg" alt="JB Weld Applied to Lock Mechanism Hinge Plate" width="640" height="426" /></a>
JB Weld Applied to Lock Mechanism Hinge Plate

<a title="Pannier #1 Latch Locks Use Key #069 by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/17559222103"><img src="https://c4.staticflickr.com/8/7793/17559222103_6e7c1d58ee_z.jpg" alt="Pannier #1 Latch Locks Use Key #069" width="640" height="426" /></a>
Pannier #1 Latch Locks Use Key #069

<a title="Panniers Mounted by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/18150081926"><img src="https://c4.staticflickr.com/8/7755/18150081926_30ffbb9630_z.jpg" alt="Panniers Mounted" width="640" height="426" /></a>
Panniers Mounted

<a title="Panniers Mounted by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/17555979783"><img src="https://c4.staticflickr.com/8/7770/17555979783_ecc62549d5_z.jpg" alt="Panniers Mounted" width="640" height="426" /></a>
Panniers Mounted

<a title=". by Brook Reams, on Flickr" href="https://www.flickr.com/photos/brook-reams/17988871660"><img src="https://c4.staticflickr.com/8/7778/17988871660_349307a346_z.jpg" alt="Panniers Mounted" width="640" height="426" /></a>
Panniers Mounted

I reckon that's better than a B+!

Nice work.

Jeff488 said:

I reckon that's better than a B+!

Nice work.

Click to expand...

Jeff,

You are kind sir. It turns out to be a bit harder than I thought to make an invisible repair. I need to find a way to keep both edges of the crack even with each other. My guess is I need a bigger piece of flat material on both sides of the crack so when I clamp them, the edges can't flex or bend.

Onward...

Best.
Brook.