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Thread: 1983 R100RS Rebuild Project Journal

  1. #166
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    1983 R100RS Install Rear Brake System

    I'm converting this RS model to a RT. The only difference in the brake system is the length of the hose from the front master cylinder to the front brake line splitter underneath the gas tank as the RT handlebars are wider so that hose is longer. The rear brake system is the same on both the RS and RT models

    I previously rebuilt the two front and one rear calipers and rebuilt the rear master cylinder. The front master cylinder was so badly corroded that I replaced it along with the entire right handlebar perch. I also installed the three disk brake rotors on the newly powder coated wheels. You can read about how I did that work here.

    Here is the documentation of how I install the rear brake system and a short video summary of the procedure.



    VIDEO: 1983 BMW R100RS/RT Install Brake System

    The master cylinder in on the right side while the rear brake caliper is on the left so there is a long steel brake line between the master cylinder and a bracket on the left, lower frame gusset where the flexible brake hose from the caliper attaches to the steel brake line. That's a long run of brake line and I use my "Air Zapper" to help pull the air out of the line.

    "Air Zapper" Vacuum Brake Bleeding Parts
    "Air Zapper" Vacuum Brake Bleeding Parts

    I finished up bleeding the rear brake system by pumping the rear brake pedal and opening and closing the caliper bleed valve to get the last bit of air out of the system. I now have a solid rear brake all set to stop.

    Rear Caliper Mounted And Ready To Stop
    Rear Caliper Mounted And Ready To Stop

    So next up is installing the front brake system.
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  2. #167
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    1983 R100RS/RT Install Front Brake System

    I'm converting this RS model to a RT. The only difference in the brake system is the length of the hose from the front master cylinder to the front brake line manifold underneath the gas tank (RT: Part# 34 32 1 241 565; RS: Part# 34 32 1 241 564). Since the RT handlebars are wider, that hose is longer. The rear brake system is the same on both the RS and RT models.

    Here is a link to the documentation of how I do this work.

    And this is a short video summarizing the procedure.



    VIDEO: 1983 BMW R100RS/RT Install Front Brake System

    I previously rebuilt the two front and one rear calipers and rebuilt the rear master cylinder. The front master cylinder was so badly corroded that I replaced it along with the entire right handlebar perch. I also installed the three disk brake rotors on the newly powder coated wheels. You can read about how I did that work here.

    Here is the link to showing how I install the rear brake system.

    I opted to use the mechanical front brake switch that mounts in the right perch instead of the original brake fluid pressure switch that mounts on the rear of the front brake manifold under the gas tank. The hole in the pressure switch can trap an air bubble making it more difficult to bleed the brakes.

    I plugged the rear hole in the front brake line manifold where the front brake light pressure switch mounts. McMaster-Carr sells a plug with copper crush washer that's perfect for this.

    McMaster Carr Stainless Steel Plug With Copper Washer
    McMaster-Carr Stainless Steel Plug With Copper Washer

    Stainless Steel Plug Installed In Front Brake Line Manifold Hole For Pressure Switch
    Stainless Steel Plug Installed In Front Brake Line Manifold Hole For Pressure Switch

    I now have brakes and the bike is getting pretty close to being finished.

    Front Brake Line Manifold Connections
    Front Brake Line Manifold Connections

    All Done-Left Side
    All Done-Left Side

    All Done-Right Side
    All Done-Right Side
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  3. #168
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    1983 R100RS Install Rear Fender Assembly

    I installed the rear fender assembly that includes the rear turn signals, tail light and brake light housing, the fender, mud flap and license plate bracket with side reflectors. This is easy work if you remove the rear wheel. But, there is a lot of hardware used and I show what goes where.

    This is a link to the detailed documentation and a short video summarizing the work.



    VIDEO: 1983 BMW R100RS Install Rear Fender And Lights

    Here are some pictures of the work.

    Rear Fender Assembly Components With Exception Of License Plate Bracket
    Rear Fender Assembly Components With Exception Of License Plate Bracket

    Front Bracket Hardware For Rear Fender
    Front Bracket Hardware For Rear Fender

    Rear Bracket Hardware For Rear Fender
    Rear Bracket Hardware For Rear Fender

    Tail Light Housing & Turn Signal Mounting Hardware
    Tail Light Housing & Turn Signal Mounting Hardware

    Tail Light Reflector Wiring-GREY-Black is Parking, GREEN-Red Is Stop Light
    Tail Light Reflector Wiring: GREY-Black is Parking, GREEN-Red Is Stop Light

    Routing Of Sub-Harness on Left Side Of Rear Fender For Tail & Turn Signal Lights
    Routing Of Sub-Harness on Left Side Of Rear Fender For Tail & Turn Signal Lights

    All Done
    All Done

    All Done
    All Done
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  4. #169
    Brook, as a metallurgical engineer, I feel obligated to comment on your use of a stainless plug and copper washer in an aluminum housing. This is a bad combo from a galvanic corrosion standpoint. Use a plain steel plug that is cad plated, zinc plated or coated with one of the zinc containing organic coatings, like Sermaguard. For the sealing washer, use one of the BMW OEM zinc plated steel washers.

  5. #170
    B Reams brook.reams's Avatar
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    Quote Originally Posted by swall View Post
    Brook, as a metallurgical engineer, I feel obligated to comment on your use of a stainless plug and copper washer in an aluminum housing. This is a bad combo from a galvanic corrosion standpoint. Use a plain steel plug that is cad plated, zinc plated or coated with one of the zinc containing organic coatings, like Sermaguard. For the sealing washer, use one of the BMW OEM zinc plated steel washers.
    Hi Swall,

    Thanks for the note. A couple things to add to your observations.

    1. Since I put Loctite on the threads and they are where contact occurs between aluminum and stainless, and Loctite is a plastic that creates a water tight and insulated connection, I doubt much, if any, galvanic potential exists that will corrode the threads if there is no electrolyte available.

    2. BMW uses stainless steel on the banjo bolt fitting on the right perch where the front brake line connects to the master cylinder (cast from aluminum or pot metal, I'm not sure which) with two copper washers, one between the steel banjo bolt and stainless steel fitting and the other between the stainless steel fitting and the aluminum/pot metal master cylinder. They use copper as it's ductility ensures a seal against the brake fluid pressure and it does not crack under compression which has been shown to happen when using aluminum crush washers. I suspect the fittings are tight enough that electrolyte (aka water) isn't able to penetrate setting up a galvanic reaction and since brake fluid is not an electrolyte, although there is galvanic potential there isn't an electrolyte to allow electron transfer.

    3. Now brake fluid is hydroscopic, so if one does not change fluid annually, corrosion can get going which was the case on the steel master cylinder fittings and inside the steel brake lines on this bike.

    That said, I'm not a metallurgical engineer, just a one time mechanical engineer who long forgot most of what was taught in the metallurgy class. :-)
    Last edited by brook.reams; 08-17-2020 at 03:37 PM.
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  6. #171
    OK, Brook, looks like you have considered the issue of corrosion and taken measures to mitigate it. It has been established that brake fluid can become an electrolyte over time with water contamination and there is a test in the SAE J1703 brake fluid spec that uses a series of 6 different metal strips immersed in brake fluid adulterated with water to evaluate the potential for galvanic corrosion. There is also the issue of galvanic corrosion on the outside of the joint from exposure to ambient moisture, particularly when road salts are present. I did an SAE B117 corrosion test one time with an aluminum master cylinder housing with a brass fitting screwed into it and corrosion developed in the crevice/joint. This result convinced the engineer to go with an aluminum plug instead of the brass.

  7. #172
    B Reams brook.reams's Avatar
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    Quote Originally Posted by swall View Post
    OK, Brook, looks like you have considered the issue of corrosion and taken measures to mitigate it. It has been established that brake fluid can become an electrolyte over time with water contamination and there is a test in the SAE J1703 brake fluid spec that uses a series of 6 different metal strips immersed in brake fluid adulterated with water to evaluate the potential for galvanic corrosion. There is also the issue of galvanic corrosion on the outside of the joint from exposure to ambient moisture, particularly when road salts are present. I did an SAE B117 corrosion test one time with an aluminum master cylinder housing with a brass fitting screwed into it and corrosion developed in the crevice/joint. This result convinced the engineer to go with an aluminum plug instead of the brass.
    Swall,

    Nonetheless, your observations are useful when considering solutions on future projects. Corrosion considerations need to be part of the answer.

    Best.
    Brook.
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  8. #173
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    1983 R100RS Install Steering Damper Mechanism

    Installation of the steering damper mechanism is straight forward. One thing that you can get wrong is aligning the number on the damper rod with the correct position of the damper rack it adjusts. I show how to get that orientation correct.

    Here is the link to the detailed procedure and to a short video summary of the installation process.




    VIDEO: 1983 BMW R100RS Install Steering Damper Mechanism
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  9. #174
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    1983 R100RS Install Exhaust System

    Putting the mufflers on this bike is exhausting. [laugh track]. Okay, I just couldn't resist that one.

    I decided to replace the exhaust system due to the amount of corrosion I found on the original one. This year/model bike has two cross-over pipes while the earlier year airheads (before the 1981 model year, or before 09/1980) had a single cross-over pipe beneath the front engine cover. The rumor is the second cross-over pipe improves engine performance over the single pipe models. I got the exhaust system from Euro MotoElectrics

    I also install the Brown's side stand that came with the bike as it attaches to the left side header bracket and the front hole of the side stand bracket uses special bolt and nut supplied with the side stand. There is also a toothed washer for the rear hole that mounts on the rear engine stud with the standard nut to keep the side stand bracket from rotating on the engine stud.

    Here is a link to the detailed installation procedure and a short video summary of the installation.



    VIDEO: 1983 BMW R100RS Install Exhaust System

    Here are some pictures.

    Header & Cross-Over Pipes From EME
    Header & Cross-Over Pipes From EME

    Front Header Pipe (Top) Is Longer Than Rear Pipe (Bottom)
    Front Header Pipe (Top) Is Longer Than Rear Pipe (Bottom)

    Exhaust Header Hardware
    Exhaust Header Hardware

    Brown's Side Stand Installed
    Brown's Side Stand Installed

    New Muffler Installed
    New Muffler Installed

    New Headers And Cross-Over Installed
    New Headers And Cross-Over Installed
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  10. #175
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    1983 R100RS Install Center And Side Stands

    I am not using the stock side stand for three reasons: the bushing and bolt are trash, it's in an inconvenient location hidden by the cylinder and lower fairing panel when extended making it hard to deploy, and the bike came with a Brown's side stand which mounts further back on the frame so it's easy to deploy. The left exhaust header bracket is secured to the Brown's side stand bracket so I installed the side stand when I installed the exhaust system.

    Brown's Side Stand
    Brown's Side Stand

    Brown's Side Stand Installed
    Brown's Side Stand Installed

    I had the center stand repaired and powder coated. I replaced the pivot bolts and bushings due to wear and tear.

    Center Stand Wear and Tear After 82,000 Miles And 37 Years
    Center Stand Wear and Tear After 82,000 Miles And 37 Years

    Repaired And Powder Coated Center Stand
    Repaired And Powder Coated Center Stand

    Here is a link showing how I do this work.

    I take the bike off the lift to test out both stands. Everything works smoothly. It's nice to have it on the center stand again :-)

    Side Stand Works
    Side Stand Works

    Center Stand Works
    Center Stand Works
    Last edited by brook.reams; 08-23-2020 at 09:06 PM.
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  11. #176
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    1983 R100RS Install Carburetors, Cables And Air Box

    I show how I remove the carburetors and airbox in this write-up.
    Since I am converting this RS model to an RT, the handlebar throttle and choke cables have to be longer and I show how to change the handlebar cables in the Bowden assembly. I installed them when I installed the handlebar perches as shown here.

    I had the air box powder coated. Although the carburetor rebuild was a couple years ago, I rode the bike less than 1,500 miles after the rebuild and they have been off the bike for about two years. I inspected the o-rings and found they are in good condition so no need to do another carburetor rebuild.

    Since I modified the engine to boost compression from 8.2:1 to 9.5:1 and had the heads bored for dual spark plugs, I have to change the carburetor jetting. This engine has the same configuration as the engine in my 1977 R100RS that has the CFO (California, Florida, Oregon) configuration, so I use the same carburetor jetting.

    When I first got the bike, I rebuilt the carburetors and "updated" the pulse-air system that fed air to the exhaust ports as shown here.
    Here is how I did the work.

    And this is a video summary of the procedure.



    VIDEO: 1983 R100RS Install Carburetors, Cables And Air Box

    Here are a few pictures from the write-up.

    Air Box Top, Air Filter And Air Box
    Air Box Top, Air Filter And Air Box

    Air Box Internal Parts And Fittings
    Air Box Internal Parts And Fittings

    Air Box Fittings
    Air Box Fittings

    Air Horn Plastic Pipes Attach To Tee With Wire Spring Clamps
    Air Horn Plastic Pipes Attach To Tee With Wire Spring Clamps

    Snap Clips Into Air Box Cover Slots
    Snap Clips Into Air Box Cover Slots

    Throttle Cable Bowden Connector Routing Next To Frame On Top Of Voltage Regulator (Right Side)
    Throttle Cable Bowden Connector Routing Next To Frame On Top Of Voltage Regulator (Right Side)

    Choke Cable Bowden Connector Housing Routing Under Starter Relay (Left Side)
    Choke Cable Bowden Connector Housing Routing Under Starter Relay (Left Side)

    Richer 170 Main Jet Installed In Jet Carrier
    Richer 170 Main Jet Installed In Jet Carrier

    Adjust Throttle Stop Screw So It Just Contacts Throttle Arm Using A Piece Of Paper
    Adjust Throttle Stop Screw So It Just Contacts Throttle Arm Using A Piece Of Paper

    All Done-Left Side
    All Done-Left Side

    All Done-Right Side
    All Done-Right Side

    All Done-Top
    All Done-Top
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  12. #177
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    1983 R100RS/RT First Engine Start Milestone

    The first engine start is always a major milestone on a project. I usually perform this earlier in the build than I am on this project. But, my gas tank and the other parts that I had painted have been delayed coming back, so I've done everything else I can do until I got the gas tank in hand. This Friday, I picked it up and installed it.

    I made a detailed check list prior to starting the engine so I wouldn't forget something and improve the likelihood the engine will start.

    Here is a link to the procedure I followed to prepare for the engine start, and how I performed the all important initial bedding in of the new piston rings with the new Nikasil coated cylinders.

    I also made a summary video of the procedure and recorded the engine start.



    VIDEO: 1983 BMW R100RS/RT First Engine Start
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  13. #178
    Quote Originally Posted by brook.reams View Post
    The first engine start is always a major milestone on a project. I usually perform this earlier in the build than I am on this project. But, my gas tank and the other parts that I had painted have been delayed coming back ...
    I was complaining about this very thing once to my good friend, the late Richard Wildauer. He smiled and said, "You don't understand. Painters think in geologic time."
    Paul Glaves - "Big Bend", Texas U.S.A
    "The greatest challenge to any thinker is stating the problem in a way that will allow a solution." - Bertrand Russell
    http://web.bigbend.net/~glaves/

  14. #179
    B Reams brook.reams's Avatar
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    Quote Originally Posted by PGlaves View Post
    I was complaining about this very thing once to my good friend, the late Richard Wildauer. He smiled and said, "You don't understand. Painters think in geologic time."
    Paul,

    How true. I've never had a painter refuse work, but they never tell you "I'll do that when I get to it, and am in the right mood." :-) In this case, he's a friend who moved his business to Phoenix and then ended up having to move his shop 3 times, finally having to close for awhile when his partner abandoned him and his 1/2 of the rent. Then COVID-19 intruded, and my plan to pick up the parts back in April fell through. Oh well, if they weren't here, there's less chance I'd have damaged the panels before mounting them. :-0

    Best.
    Brook.
    Last edited by brook.reams; 09-09-2020 at 11:14 PM.
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    Endeavor to Persevere || Brook's Airhead Garage-Amature Rebuild Projects
    2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  15. #180
    Registered User STEVENRANKIN's Avatar
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    Painters

    I am looking for a painter now myself. The fellow I would like to have do the job is moving and then becomes a snow bird in the winter. Next summer he is only in my area for four months and is already pretty much booked.

    Meanwhile, I am grounded from riding for the rest of this season and I have a broken RT fairing to be replaced with a newer used one but not a match with the tanks and other parts of the bike.

    Lots of car paint shops, few bike shops. Now if it were a powder coat job, no problem, I can't swing a cat without hitting one of them. LOL. St.

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