1983 R100RS Rebuild Project Journal

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. <a href="http://www.rubberchickenracinggarage.com" target="_blank" rel="noopener noreferrer">Tom Cutter at Rubber Chicken Racing Garage</a>, 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.

<a title="New SS Push Rod Tubes & Original Head Studs Installed" href="https://www.flickr.com/photos/brook-reams/49581368346/in/album-72157713244736881/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49581368346_e099c763ca_c.jpg" alt="Refinished Cylinders with New Push Rod Tubes" width="800" height="600" /></a>
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.

<a title="Rebuilt Heads-I Had Them Dual Plugged" href="https://www.flickr.com/photos/brook-reams/49611874891/in/album-72157713339451047/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49611874891_8891464244_c.jpg" alt="Randy Long's Rebuilt Heads" width="800" height="600" /></a>
Randy Long's Rebuilt Heads

<a title="Rebuilt Head with New Exhaust Valve" href="https://www.flickr.com/photos/brook-reams/49611357718/in/album-72157713339451047/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49611357718_84174d481d_c.jpg" alt="Rebuilt Head with New Exhaust Valve and Dual Plug Conversion" width="800" height="600" /></a>
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.

<a title="Red Tape Means Not Ready Yet" href="https://www.flickr.com/photos/brook-reams/49612127297/in/album-72157713339451047/" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49612127297_488b9ec348_c.jpg" alt="Red Tape Means Not Ready Yet" width="800" height="600" /></a>
Red Tape Means Not Ready Yet

<a title="All Done" href="https://www.flickr.com/photos/brook-reams/49611870581/in/album-72157713339451047/" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49611870581_3a20ae81dc_c.jpg" alt="All Done" width="800" height="600" /></a>
All Done

Here is written documentation of the procedure:
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/11-bmw-1983-r100rs-install-top-end/">11 BMW 1983 R100RS Install Top End</a></li>
</ul>And here is a video of the procedure.


<strong>VIDEO: <em><span style="text-decoration: underline;">1983 BMW R100RS Install Engine Top End</span></em></strong>

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.
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/33-bmw-1983-r100rs-remove-drive-shaft/">33 BMW 1983 R100RS Remove Drive Shaft</a></li>
</ul>Now that the swing arm is back, it's time to install the drive shaft and new swing arm bearings.

<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

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.

<a title="Cycle Works Drive Shaft Removal Tool Components" href="https://www.flickr.com/photos/brook-reams/48140710616/in/album-72157713519841331/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/48140710616_3c28f86483_c.jpg" alt="Cycle Works Drive Shaft Spring Compression Tool Components" width="800" height="600" /></a>
Cycle Works Drive Shaft Spring Compression Tool Components

<a title="Drive Shaft Parts" href="https://www.flickr.com/photos/brook-reams/49670079631/in/album-72157713519841331/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49670079631_1632a37302_c.jpg" alt="Drive Shaft Parts" width="800" height="600" /></a>
Drive Shaft Parts

<a title="All Done-Rear Drive End" href="https://www.flickr.com/photos/brook-reams/49669599403/in/album-72157713519841331/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49669599403_bf3a6108a3_c.jpg" alt="All Done-Rear Drive End" width="800" height="600" /></a>
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.

<a title="Front Face of Bearing With Dust Seal" href="https://www.flickr.com/photos/brook-reams/49673823646/in/album-72157713533121706/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49673823646_355a3d198e_c.jpg" alt="Front Face of Bearing With Dust Seal" width="800" height="600" /></a>
Front Face of Bearing With Dust Seal

<a title="Dust Cover Removed" href="https://www.flickr.com/photos/brook-reams/49673281128/in/album-72157713533121706/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49673281128_d97440702d_c.jpg" alt="Dust Seal Removed" width="800" height="600" /></a>
Dust Seal Removed

<a title="New Bearing with Sleeve That Points Outside" href="https://www.flickr.com/photos/brook-reams/49674103382/in/album-72157713533121706/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49674103382_7f326b9dcc_c.jpg" alt="Front Face Of New Bearing Has A Sleeve" width="800" height="600" /></a>
Front Face Of New Bearing Has A Sleeve

<a title="Driving The Bearing Into The Swing Arm" href="https://www.flickr.com/photos/brook-reams/49673280528/in/album-72157713533121706/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49673280528_0ccbb1c858_c.jpg" alt="Driving The Bearing Into The Swing Arm with Just The Socket Was Easier" width="800" height="600" /></a>
Driving The Bearing Into The Swing Arm with Just The Socket Was Easier

You can read about how I do this work here:
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/33-bmw-r100rs-install-drive-shaft/" aria-current="page">33 BMW 1983 R100RS Install Drive Shaft</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>
And here are links to two short videos summarizing how I do the work.

<strong>VIDEO: <em><span style="text-decoration: underline;">1983 BMW R100RS Install Drive Shaft</span></em></strong>
https://youtu.be/GvcegHx90Ho

<strong>VIDEO: <em><span style="text-decoration: underline;">1983 BMW R100RS Install Swing Arm Bearings</span></em></strong>
https://youtu.be/_RtxM-FY9s4

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:
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/51-bmw-r100rs-repair-refinish-paint/">51 BMW R100RS Repair, Refinish, Paint</a></li>
</ul>
Here are a couple before and after pictures from the work I've done so far.

<a title="Rear Brembo Caliper With Retaining Bolts Removed" href="https://www.flickr.com/photos/brook-reams/48458704222/in/album-72157710099334526/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/48458704222_dbaa1c3a0e_c.jpg" alt="BEFORE: Brembo Rear Brake Caliper" width="800" height="600" /></a>
BEFORE: Brembo Rear Brake Caliper

<a title="Pad Cover Installed" href="https://www.flickr.com/photos/brook-reams/48482521102/in/album-72157710099334526/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/48482521102_ef8d2f2685_c.jpg" alt="AFTER: Repainted & Rebuilt" width="800" height="600" /></a>
AFTER: Repainted & Rebuilt[/caption]

<a title="Left Carburetor Top" href="https://www.flickr.com/photos/brook-reams/15873291754/in/album-72157650334262247/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/7336/15873291754_580b5f23a2_c.jpg" alt="BEFORE: Left Carburetor Top" width="800" height="600" /></a>
BEFORE: Left Carburetor Top[/caption]

<a title="Carburetor Ready for Cable Removal" href="https://www.flickr.com/photos/brook-reams/16308370084/in/album-72157651106718637/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/7587/16308370084_3c2949f350_c.jpg" alt="BEFORE: Left Carburetor Choke Side" width="800" height="532" /></a>
BEFORE: Left Carburetor Choke Side

<a title="Inside of Carburetor" href="https://www.flickr.com/photos/brook-reams/16930744135/in/album-72157651106718637/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/8688/16930744135_086b85b440_c.jpg" alt="AFTER: Choke Side of Carburetor" width="532" height="800" /></a>
AFTER: Choke Side of Carburetor

<a title="Top Side of Carburetor" href="https://www.flickr.com/photos/brook-reams/16929452862/in/album-72157651106718637/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/8698/16929452862_2f49c0b7b2_c.jpg" alt="AFTER: Top Side of Carburetor" width="800" height="532" /></a>
AFTER: Top Side of Carburetor

<a title="Before-Inner Timing Cover" href="https://www.flickr.com/photos/brook-reams/49678056801/in/album-72157713502240312/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49678056801_710acfc031_c.jpg" alt="BEFORE-Inner Timing Cover" width="800" height="600" /></a>
BEFORE-Inner Timing Cover

<a title="Before-Inner Timing Cover" href="https://www.flickr.com/photos/brook-reams/49678056711/in/album-72157713502240312/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49678056711_b877e65f5e_c.jpg" alt="BEFORE-Inner Timing Cover" width="800" height="600" /></a>
BEFORE-Inner Timing Cover

<a title="Finished Inner Timing Cover" href="https://www.flickr.com/photos/brook-reams/49678056491/in/album-72157713502240312/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49678056491_6ef9839ce6_c.jpg" alt="Finished Inner Timing Cover" width="800" height="600" /></a>
Finished Inner Timing Cover

<a title="Front Engine Cover with Corrosioin" href="https://www.flickr.com/photos/brook-reams/49678056461/in/album-72157713502240312/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49678056461_e582db5b3e_c.jpg" alt="Front Engine Cover with Corrosion" width="800" height="600" /></a>
Front Engine Cover with Corrosion

<a title="Refinished Front Engine Cover" href="https://www.flickr.com/photos/brook-reams/49692895687/in/album-72157713502240312/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49692895687_316cc5b738_c.jpg" alt="Refinished Front Engine Cover" width="800" height="600" /></a>
Refinished Front Engine Cover

<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="Rear Drive Was Painted Black" width="800" height="600" /></a>
Rear Drive Was Painted Black

<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="Rear Drive Was Painted Black" width="600" height="800" /></a>
Rear Drive Was Painted Black

<a title="Refinished Rear Drive" href="https://www.flickr.com/photos/brook-reams/49663874883/in/album-72157713502240312/" 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

<a title="Refinished Rear Drive" href="https://www.flickr.com/photos/brook-reams/49663874833/in/album-72157713502240312/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49663874833_8f4c38618f_c.jpg" alt="Refinished Rear Drive" width="800" height="600" /></a>
Refinished Rear Drive

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.

1983 R100RS Replace Main Wiring Harness & Lengthen Handlebar Switch Wires

Folks,

I'm going to replace the main wiring harness. This requires removing a number of connections inside the headlight shell, pulling the old harness out of the headlight shell and then installing the new harness and connecting the wires to the proper terminals on the wiring block, the headlight relay and the turn signal relay. You do not have to remove the connections from the left and right handlebar switches to replace the main wiring harness.

Bur, since I am converting this 1983 R100RS into an RT configuration and the RT handlebars are much longer than the RS bars, the stock RS handlebar switch wires are too short; 230 mm (9 inches) vs.the RT switch's 520 mm (20 inches). However, someone replaced the left handlebar switch with an RT length switch, so that's fortunate. But the right handlebar switch, that was also replaced at some point, has shorter 380 mm (about 15 inches) wires; they are longer than RS wires, but still too short. Since BMW does not sell the RT switches anymore, I will lengthen the wires in the right handlebar switch cable.

Here is how I did that work.
<ul class="children">
<li class="page_item page-item-8066"><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 R100RS/RT Replace Main Wiring Harness</a></li>
<li class="page_item page-item-8100"><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/61-bmw-1983-r100rs-rt-lengthen-handlebar-switch-wires/">61 BMW R100RS/RT Lengthen Handlebar Switch Wires</a></li>
</ul>
And here are videos summarizing the procedure.

<strong>VIDEO: <span style="text-decoration: underline;"><em>1983 BMW R100RS Replace Main Wiring Harness</em></span></strong>

<strong>VIDEO: <em><span style="text-decoration: underline;">1983 BMW R100RS Lengthen Handlebar Switch Wires</span></em></strong>

Here is the new main wiring harness I got from Euro MotoElectrics. BMW not longer makes this harness.

<a title="New Main Wiring Harness" href="https://www.flickr.com/photos/brook-reams/49696368562/in/album-72157713615889507/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49696368562_a96787e01a_c.jpg" alt="New Main Wiring Harness From Euro MotoElectrics" width="800" height="600" /></a>
New Main Wiring Harness From Euro MotoElectrics

Here is the final product.

<a title="All Done" href="https://www.flickr.com/photos/brook-reams/49727574548/in/album-72157713716504021/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49727574548_941c588123_c.jpg" alt="Both Handlebar Switches Are RT Length" width="800" height="450" /></a>
Both Handlebar Switches Are RT Length

<a title="All Done with RT Length Handlebar Switch Wires" href="https://www.flickr.com/photos/brook-reams/49728798451/in/album-72157713615889507/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49728798451_3f30ed4acd_c.jpg" alt="New Main Wiring Harness with RT Length Handlebar Switch Wires Installed" width="800" height="450" /></a>
New Main Wiring Harness with RT Length Handlebar Switch Wires Installed

Same problem

Hey Brooke, I have a similar problem with switch wire length. My 78 RS horn and light switch has gone to meet its maker and I needed to replace it. Found one from an R90S but it is too short for the RS, no slack for the handlebars to turn on the RS versus the headlight turning with the handlebars on the S.

Thank for the video. St.

That's nice that you can still get those harnesses.

Going back a bit, are those BMW pistons?

Rinty said:

That's nice that you can still get those harnesses.

Going back a bit, are those BMW pistons?

Click to expand...

Rinty,

Yes, those are available at BMW dealers. They are European issue. That said, Siebenrock also makes 9.5:1 pistons and they are rumored to be a bit lighter, which is a good thing for reduction of vibration and stress on the connecting rods.

Best.
Brook.

Brook
the documentation you provide is great! Thank you!
Curious Do you have a target finish date?
Best regards
Nick

nickrides said:

Brook
the documentation you provide is great! Thank you!
Curious Do you have a target finish date?
Best regards
Nick

Click to expand...

Hi Nick,

Well sure. When it's done.

Unlike the last project when I had to finish the 1977 RS in time to ride it to the 40th anniversary rally to meet Hans Muth, this one is being worked on with no time constraint. In the back of my mind, I suspect it will be done in the summer sometime, depending on what unexpected stuff I may run into.

Best.
Brook.

1983 BMW R100RS Replace Steering Stem Bearings

************************************************** ******
THIS POST HAS BEEN UPDATED TO INCLUDE A NEW VIDEO.
I left out the section that shows installation of the outer races with the Cycle Works tool. The video link goes to an edited version of the video.
************************************************** ******
The steering head bearings are roller bearings. But, roller bearings rely on the roller rotating to keep distributing grease between the roller and the outer race to prevent metal-on-metal contact. However, the front forks spend most of their time in one position and are subject to shock loads as the front end goes over bumps. This means grease gets extruded from between the rollers in the inner race and the outer race allowing metal-to-metal contact, and the shock loads pound the roller against the outer race creating grooves in the race. This creates notchy steering, and when it's really bad, you can feel resistance when trying to turn the forks from the center position.

When I removed the steering head bearings, they showed the distinctive vertical stripes indicating the outer race has Brinelling, which is the groove pounded into the outer race.

<a title="Original Bottom Outer Race Showing Moderate Brinelling" href="https://www.flickr.com/photos/brook-reams/49740007507/in/album-72157713767816456/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49740007507_7ac7235e95_c.jpg" alt="Original Bottom Outer Race Showing Moderate Brinelling" width="800" height="600" /></a>
Original Bottom Outer Race Showing Moderate Brinelling

I use the Cycle Works tools for removing and installing the steering head bearings. See the "Replace Steering Head Bearings" section below for a link that shows the Cycle Works tools are assembled and used.

<a title="Outer Race Puller Plate Parts" href="https://www.flickr.com/photos/brook-reams/32815001410/in/album-72157713767816456/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/2847/32815001410_6d1ab98864_c.jpg" alt="Outer Race Puller Plate Parts" width="800" height="600" /></a>
Cycle Works Outer Race Puller Plate Parts

<a title="Cycle Works Steering Stem Lower Bearing Puller Tools" href="https://www.flickr.com/photos/brook-reams/32352789884/in/album-72157713767816456/" data-flickr-embed="true"><img src="https://live.staticflickr.com/5814/32352789884_095f36fda4_c.jpg" alt="Cycle Works Steering Stem Lower Bearing Puller Tools" width="800" height="600" /></a>
Cycle Works Steering Stem Lower Bearing Puller/Install Tool Parts

<a title="Outer Bearing Race Installation Tool Parts" href="https://www.flickr.com/photos/brook-reams/32352791654/in/album-72157713767816456/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/705/32352791654_50a24a5252_c.jpg" alt="Outer Bearing Race Installation Tool Parts" width="800" height="600" /></a>
Cycle Works Outer Bearing Race Installation Tool Parts

I removed the old outer races and the inner race on the bottom of the steering stem. Then I refinished the lower fork brace and then installed the new lower inner bearing race and then installed the steering stem in the steering head.

<a title="Draw Bar Top Cover Detail with Top Outer Race" href="https://www.flickr.com/photos/brook-reams/49739681321/in/album-72157713767816456/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49739681321_90145f27c4_c.jpg" alt="Cycle Works Draw Bar Top Cover Detail with Top Outer Race" width="800" height="600" /></a>
Cycle Works Draw Bar Top Cover Detail Used To Install Top Outer Race

<a title="Looks Like Wheel Bearing Grease Was Used and Melted Making A Mess" href="https://www.flickr.com/photos/brook-reams/49739154098/in/album-72157713767816456/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49739154098_d37dae2a69_c.jpg" alt="Looks Like Wheel Bearing Grease Was Used and Melted Making A Mess" width="800" height="600" /></a>
Looks Like Wheel Bearing Grease Was Used and Melted Making A Mess

<a title="Pulling The Lower Inner Race" href="https://www.flickr.com/photos/brook-reams/49740024347/in/album-72157713767816456/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49740024347_2a71281b74_c.jpg" alt="Pulling The Lower Inner Race" width="800" height="600" /></a>
Pulling The Lower Inner Race

<a title="Final Product" href="https://www.flickr.com/photos/brook-reams/49740056167/in/album-72157713767816456/" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49740056167_b9ae7b65e2_c.jpg" alt="Final Product" width="800" height="600" /></a>
Refinished Lower Fork Brace Looking Like New Again

<a title="Steering Stem Nut Installed" href="https://www.flickr.com/photos/brook-reams/49751526146/in/album-72157713767816456/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49751526146_d2b26cee59_c.jpg" alt="Steering Stem Nut Installed" width="800" height="600" /></a>
Steering Stem Nut Installed on Steering Stem

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

• 31 BMW 1983 R100RS Replace Steering Head Bearings

And here is a video summarizing how I remove and install the steering head bearings.

VIDEO: 1983 BMW R100RS Replace Steering Head Bearings

 

Nice
om

Video on pulling the races was very informative, Brooks. I have seen those blind bearing pullers before, but never saw one being used.

1983 BMW R100RS Install EME Optical-Electronic Ignition System

When I had the heads rebuilt by Randy Long I had him modify them for dual plugs. I have made that modification on two other bikes and I like the improvement in gas mileage and the smooth running even on lower octane gas. So I have to replace the stock coils with coils that have two secondary ports so each coil connects to two spark plug wires.

This bike came with a BMW electronic ignition that includes a "bean can" with Hall effect sensors that act like mechanical points.

<a title="Ignition Sensor (aka "Bean Can")" href="https://www.flickr.com/photos/brook-reams/49165781727/in/album-72157712051528583/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49165781727_090f15a167_c.jpg" alt="BMW Stock Ignition Sensor (aka "Bean Can") with Hall Effect Sensors" width="800" height="600" /></a>
BMW Stock Ignition Sensor (aka "Bean Can") with Hall Effect Sensors

The Hall effect sensors use a rotating magnetic field to open an electronic switch in the Hall effect sensor to stop current flow in the coil primary triggering a large voltage in the coil secondary. This is exactly what mechanical points do to trigger a high voltage spark in the spark plugs.

There have been some issues with the BMW electronic ignition. One in particular is that Hall effect sensors do not like heat and fail over time. When they do, you are stranded unless you have a second bean can with you. You can't remove and disassemble the bean can by the side of the road.

I decided to remove the stock BMW ignition system and install a system that uses an optical switch for the points and a electronic ignition control module from <a href="http://www.euromotoelectrics.com" target="_blank" rel="noopener noreferrer">Euro MotoElectrics</a>. The ignition control module has three different ignition advance curves you can select from including one that works well with dual plug engines.

<a title="EME Optical-Electronic Ignition Kit" href="https://www.flickr.com/photos/brook-reams/49806677112/in/dateposted-public/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49806677112_83e31960b9.jpg" alt="EME Optical-Electronic Ignition Kit" width="500" height="371" /></a>
EME Optical-Electronic Ignition Kit

Since I have dual plug heads, I also install dual port coils.

<a title="EME Enduralast 1.5 Ohm, Dual-Port Coil Kits" href="https://www.flickr.com/photos/brook-reams/49787077622/in/album-72157713934436352/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49787077622_3b5559f52f_c.jpg" alt="EME Enduralast 1.5 Ohm Dual-Port Coil Kits with Hardware" width="800" height="600" /></a>
EME Enduralast 1.5 Ohm Dual-Port Coils with Hardware

You can read about how I do this work here:
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/12-bmw-r100rs-install-eme-optical-electronic-ignition-system/">12 BMW R100RS Install EME Optical-Electronic Ignition System</a></li>
</ul>
And, this is a video summary of the procedure.


<strong>VIDEO: <em><span style="text-decoration: underline;">1983 BMW R100RS Install Euro MotoElectrics Optical-Electronic Ignition System</span></em></strong>

Here is what the final installation looks like.

<a title="Optical Trigger Cable Routing From Trigger Assembly" href="https://www.flickr.com/photos/brook-reams/49795777462/in/album-72157713934436352/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49795777462_ed4607a3d1_c.jpg" alt="Optical Trigger Cable Routing From Trigger Assembly Around Stator Housing" width="800" height="600" /></a>
Optical Trigger Assembly with Timing Wheel Mounted On Alternator Rotor

<a title="Wires From Optical Trigger (Smaller in Middle) and To Coils Installed In Socket Of Ignition Control Unit" href="https://www.flickr.com/photos/brook-reams/49794924398/in/album-72157713934436352/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49794924398_0e5e4527f0_c.jpg" alt="Wires From Optical Trigger Module Cable (Smaller Wire in Middle) and The Cable of Coil Wires I Made Are Installed In The Terminal Plug Of The Ignition Control Unit" width="800" height="600" /></a>
Ignition Control Module Mounted On Top Of EME Electronic Voltage Regulator

<a title="Left Side Coil Gets Red Wire From Ignition Control Unit & Brown Ground Wire On Coil Bracket Bolt" href="https://www.flickr.com/photos/brook-reams/49795775777/in/album-72157713934436352/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49795775777_e6445bb61c_c.jpg" alt="Left Side Coil Gets RED Wire From Ignition Control Unit & BROWN Ground Wire On Coil Bracket Bolt" width="800" height="600" /></a>
Dual Plug Coils Mount Where Original Coils Mounted

1983 BMW R100RS Remove, Refinish, Install Disk Brake Rotors

I'm going to powder coat the wheels, so I remove the disk brake rotors. I refurbish the three rotors to remove grunge and get the patina on the disk carriers back to factory condition. I also clean out the holes and sand the disks so the new disk pads will bed in and not get fouled from brake pad grunge baked onto the rotors or dirt and grunge lodged inside the disk brake rotor holes.

Here are all the details about how I do this work and a short video summarizing the work.
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/34-bmw-1983-r100rs-remove-refinish-install-disk-brake-rotors/">34 BMW 1983 R100RS Remove, Refinish, Install Disk Brake Rotors</a></li>
</ul>

<strong>VIDEO: <em><span style="text-decoration: underline;">1983 R100RS Remove-Refurbish-Install Disk Brake Rotors</span></em></strong>

Here are a couple pictures of before and after.

<a title="Rear Wheel Left Side" href="https://www.flickr.com/photos/brook-reams/49771876022/in/album-72157713889022063/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49771876022_d73b26690e_c.jpg" alt="Rear Wheel Left Side" width="800" height="600" /></a>
Rear Wheel Left Side

<a title="Rear Disk Brake Rotor Mounts To Wheel With Five Bolts Secured By Tabs On Retaining Strips" href="https://www.flickr.com/photos/brook-reams/49774374487/in/album-72157713889022063/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49774374487_feecd2017c_c.jpg" alt="Rear Disk Brake Rotor Mounts To Wheel With Five Bolts Secured By Tabs On Retaining Strips" width="800" height="600" /></a>
Rear Disk Brake Rotor Mounts To Wheel With Five Bolts Secured By Tabs On Retaining Strips

<a title="Rear Disk Brake Rotor Mounting Hardware Detail" href="https://www.flickr.com/photos/brook-reams/49774042806/in/album-72157713889022063/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49774042806_40dcfc0c21_c.jpg" alt="Rear Disk Brake Rotor Mounting Hardware Detail" width="800" height="600" /></a>
Rear Disk Brake Rotor Mounting Hardware Detail

<a title="Use Wood Blocks To Protect Front Rotors From Damage When Working On The Wheel" href="https://www.flickr.com/photos/brook-reams/49774091991/in/album-72157713889022063/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49774091991_82f9e8b1bf_c.jpg" alt="Use Wood Blocks To Protect Front Rotors From Damage When Working On The Wheel" width="800" height="600" /></a>
Use Wood Blocks To Protect Front Rotors From Damage When Working On The Wheel

<a title="Left Side Disk Brake Rotor Has Locking Nuts" href="https://www.flickr.com/photos/brook-reams/49773563333/in/album-72157713889022063/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49773563333_f75e684eae_c.jpg" alt="Left Side Disk Brake Rotor Has Locking Nuts" width="800" height="600" /></a>
Front Left Side Disk Brake Rotor Has Locking Nuts

<a title="Right Side Disk Brake Rotor Has Allan Head Bolts" href="https://www.flickr.com/photos/brook-reams/49774092201/in/album-72157713889022063/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49774092201_6e8c396140_c.jpg" alt="Right Side Disk Brake Rotor Has Allan Head Bolts" width="800" height="600" /></a>
Front Right Side Disk Brake Rotor Has Allan Head Bolts

<a title="Front Wheel Paint Is In Bad Shape" href="https://www.flickr.com/photos/brook-reams/49771867487/in/album-72157713880054883/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49771867487_ec5ff206a3_c.jpg" alt="BEFORE: Front Wheel Paint Is In Bad Shape" width="800" height="600" /></a>
Front Wheel Paint Is In Bad Shape

<a title="Rotor Mounting Plate Front Side Grunge" href="https://www.flickr.com/photos/brook-reams/49840018562/in/album-72157713889022063/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49840018562_2d3cff60db_c.jpg" alt="Rotor Carrier Front Side Grunge" width="800" height="600" /></a>
Rotor Carrier Front Side Grunge

<a title="Disk After Bead Blasting at 40 PSI" href="https://www.flickr.com/photos/brook-reams/49839173158/in/album-72157713889022063/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49839173158_30c2be0890_c.jpg" alt="Front Side Carrier After Bead Blasting at 40 PSI" width="800" height="600" /></a>
Front Side Carrier After Bead Blasting at 40 PSI

<a title="Powder Coated Wheels" href="https://www.flickr.com/photos/brook-reams/49843329008/in/album-72157713880054883/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49843329008_afdd7e838e_c.jpg" alt="AFTER: Powder Coated Wheels in White" width="800" height="600" /></a>
AFTER: Powder Coated Wheels in White

<a title="Brake Disk Rotors Installed On Newly Powder Coated Wheels" href="https://www.flickr.com/photos/brook-reams/49844266817/in/album-72157713889022063/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49844266817_6629423642_c.jpg" alt="Brake Disk Rotors Installed On Newly Powder Coated Wheels" width="800" height="450" /></a>
Brake Disk Rotors Installed On Newly Powder Coated Wheels

I think the white snowflakes look great!


Sent from my iPhone using Tapatalk

Did you measure the thickness of the brake rotors? I found that the front brake rotors on my 77RS were just below the minimum thickness at about 85k miles. These are being replaced with EBC rotors.

robsryder said:

Did you measure the thickness of the brake rotors? I found that the front brake rotors on my 77RS were just below the minimum thickness at about 85k miles. These are being replaced with EBC rotors.

Click to expand...

Hi robsryder,

I show that in the video and in the documentation. Mine are about 5-5.5 mm thick. The minimum stamped on the disk carrier is 0.18 inches (about 4.6 mm).

Best.
Brook.

1983 R100RS/RT Replace Wheel Bearings

This bike has 83,000+ miles on it and the wheel bearings are of unknown condition. So I replace them and set the wheel bearing preload. I also had the wheels powder coated after I removed the old bearings, so I had to also remove the disk brake rotors. I show how I remove, refinish and install the disk brake rotors in this document.
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/34-bmw-1983-r100rs-remove-refinish-install-disk-brake-rotors/">34 BMW 1983 R100RS Remove, Refinish, Install Disk Brake Rotors</a></li>
</ul>Of course, you can remove the wheel bearings without removing the disk brake rotors.

Here is a link to the documentation about how I do this work and to a video summary.
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/36-bmw-r100rs-replace-wheel-bearings/">36 BMW R100RS Replace Wheel Bearings</a></li>
</ul>

<strong>VIDEO: <em><span style="text-decoration: underline;">1983 BMW R100RS Replace Wheel Bearings and Set Bearing Preload</span></em></strong>

And some pictures highlighting the work.

<a title="Wheel Bearing Parts, Left-to-Right: Dust/Grease Seals (Rear Right at Bottom); Top Hats; Wheel Bearings" href="https://www.flickr.com/photos/brook-reams/49851867763/in/album-72157713907660043/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49851867763_f45cbcd19d_c.jpg" alt="Wheel Bearing Parts, Left-to-Right: Dust/Grease Seals (Rear Right at Bottom); Top Hats; Wheel Bearings" width="800" height="600" /></a>
Wheel Bearing Parts Left-to-Right (Right Rear at Bottom): Grease Seals ; Top Hats; Wheel Bearings

<a title="Cycle Works Bearing Puller Kit" href="https://www.flickr.com/photos/brook-reams/8616664143/in/album-72157713907660043/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/8263/8616664143_8ffa4f09a8_c.jpg" alt="Cycle Works Swing Arm Bearing Puller Kit-Works On Wheel Bearings As Well" width="800" height="600" /></a>
Cycle Works Swing Arm Bearing Puller Kit-Works On Wheel Bearings As Well

<a title="Rear Wheel Bearing Inner Race Removed" href="https://www.flickr.com/photos/brook-reams/49778528753/in/album-72157713907660043/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49778528753_358b81f067_c.jpg" alt="Rear Wheel Bearing Outer Race Removed" width="800" height="600" /></a>
Rear Wheel Bearing Outer Race Removed

<a title="Rear Wheel Center Pipe" href="https://www.flickr.com/photos/brook-reams/49857374466/in/album-72157713907660043/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49857374466_f32b992525_c.jpg" alt="Rear Wheel Center Pipe With Plastic Sleeves On Each End" width="800" height="450" /></a>
Rear Wheel Center Pipe With Plastic Sleeves On Each End

<a title="Powder Coated Wheels" href="https://www.flickr.com/photos/brook-reams/49843329008/in/album-72157713880054883/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49843329008_afdd7e838e_c.jpg" alt="AFTER: Powder Coated Wheels in White" width="800" height="600" /></a>
Powder Coated Wheels in White

<a title="Driving Outer Race To Proper Depth" href="https://www.flickr.com/photos/brook-reams/49852702967/in/album-72157713907660043/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49852702967_e2b56c84fa_c.jpg" alt="Driving Outer Race To Proper Depth with Cycle Works Aluminum Rectangle From Swing Arm Bearing Race Tool" width="800" height="600" /></a>
Driving Outer Race To Proper Depth with Cycle Works Aluminum Rectangle From Swing Arm Bearing Race Tool

<a title="String Evenly Wrapped Around Sleeve" href="https://www.flickr.com/photos/brook-reams/49857601012/in/album-72157713907660043/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49857601012_e772b83d6e_c.jpg" alt="String Evenly Wrapped Around Sleeve" width="800" height="600" /></a>
String Evenly Wrapped Around Sleeve

<a title="Using Spring Scale To Measure Preload Force-1" href="https://www.flickr.com/photos/brook-reams/49857816987/in/album-72157713907660043/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49857816987_337356787c_c.jpg" alt="Walking With Spring Scale To Measure Preload Force" width="800" height="450" /></a>
Walking With Spring Scale To Measure Preload Force

<a title="Front Wheel Preload-Four 0.05 mm Shims and Sanded Wedding Band" href="https://www.flickr.com/photos/brook-reams/49860904728/in/album-72157713907660043/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49860904728_63f06edde1_c.jpg" alt="Front Wheel Preload-Four 0.05 mm Shims and Sanded Wedding Band" width="800" height="600" /></a>
Front Wheel Preload-Four 0.05 mm Shims and Sanded Wedding Band

<a title="Grease Seal and Top Hat Installed" href="https://www.flickr.com/photos/brook-reams/49861748382/in/album-72157713907660043/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49861748382_57402f7618_c.jpg" alt="Grease Seal and Top Hat Installed" width="800" height="600" /></a>
Grease Seal and Top Hat Installed

<a title="Finished Wheels" href="https://www.flickr.com/photos/brook-reams/49865119016/in/album-72157713907660043/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49865119016_4da80a6862_c.jpg" alt="Finished Wheels" width="800" height="600" /></a>
Finished Wheels

1983 R100RS/RT Rebuild Forks With Race Tech Cartridge Emulators

I'm rebuilding the forks and I'm going to install the <a href="https://www.racetech.com/page/id/152" target="_blank" rel="noopener noreferrer">Race Tech Gold Gold Valve Cartridge Emulators</a>.

<a title="Race Tech Cartridge Emulator Kit with Separate Damper Rod Adapters" href="https://www.flickr.com/photos/brook-reams/49814967993/in/album-72157714030023857/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49814967993_140b21f1f6_c.jpg" alt="Race Tech Cartridge Emulator Kit [Part#: FEGV S3301] with Separate Damper Rod Adapters [Part#: FPEV AD3301P]" width="800" height="600" /></a>
Race Tech Cartridge Emulator Kit [Part#: FEGV S3301] with Separate Damper Rod Adapters [Part#: FPEV AD3301P]

This is the first time I have used them. I've heard that they make a significant improvement in handling and compliance compared to a damper rod design.

The stock springs can't be used with the cartridge emulators so I install the correct Race Tech springs based on my specifications.

<a title="Race Tech Fork Spring Kit" href="https://www.flickr.com/photos/brook-reams/49835164282/in/album-72157714030023857/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49835164282_a820707816_c.jpg" alt="Race Tech Fork Spring Kit" width="800" height="600" /></a>
Race Tech Fork Spring Kit

You can read all the details of how I do this work here.
<ul>
<li><a href="https://brook.reams.me/bmw-motorcycle-rebuilds/1983-bmw-r100rs-rebuild-project-index/31-bmw-r100rs-rt-rebuild-forks-with-race-tech-cartridge-emulators/">31 BMW R100RS/RT Rebuild Forks With Race Tech Cartridge Emulators</a></li>
</ul>And this is a video summarizing the work.


<strong>VIDEO: <em><span style="text-decoration: underline;">1983 BMW R100RS Rebuild Forks with Race Tech Cartridge Emulators</span></em></strong>

I refreshed the wearable components using a fork rebuild kit I got from Tom Cutter at <a href="http://www.rubberchickenracinggarage.com" target="_blank" rel="noopener">Rubber Chicken Racing Garage</a>.

The damper rods have to be modified so there are six compression damping holes in the bottom of the rod. Race Tech supplies a piece of 3/4 inch PVC to make fork spring preload spacers to achieve the correct preload based on my specifications.

<a title="Damper Rod Showing Parts Order" href="https://www.flickr.com/photos/brook-reams/49827360823/in/album-72157714030023857/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49827360823_d21172e5bd_c.jpg" alt="Damper Rod Showing Parts Order-(L) Bottom; (R) Top" width="800" height="600" /></a>
Damper Rod Showing Parts Order-(L) Bottom; (R) Top

<a title="Two Of The Four Additional Holes Drilled at 10 mm On Center" href="https://www.flickr.com/photos/brook-reams/49827360458/in/album-72157714030023857/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49827360458_b383312c1b_c.jpg" alt="Two Of The Four Additional Holes Drilled at 10 mm On Center" width="800" height="600" /></a>
Two Of The Four Additional Holes Drilled at 10 mm On Center and 90 Degrees Rotation From Each Other

I repainted the fork lower sliders as they had a lot of stone chips.

<a title="Fork Lower Slide Dings" href="https://www.flickr.com/photos/brook-reams/49899723621/in/album-72157714030023857/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49899723621_3f2ed8f634_c.jpg" alt="Fork Lower Slider Dings" width="800" height="600" /></a>
Fork Lower Slider Dings

<a title="Painted Lower Fork Sliders" href="https://www.flickr.com/photos/brook-reams/49899205183/in/album-72157714030023857/" target="_blank" rel="noopener noreferrer" data-flickr-embed="true"><img src="https://live.staticflickr.com/65535/49899205183_d6f44a26ee_c.jpg" alt="Repainted Lower Fork Sliders" width="800" height="600" /></a>
Repainted Lower Fork Sliders