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Thread: 1983 R100RS Rebuild Project Journal

  1. #76
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    Beautiful job on the carbs. How did you clean the body, tops and the bowls? Ultrasonic cleaner?

    Quote Originally Posted by brook.reams View Post
    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.


    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.

    Before Rebuild/Refinish

    Before-Left Carburetor
    Before-R100RS Type 94 Left Carburetor


    Rusty Screws and Cap on Dome

    Engine Side of Carburetor
    Grunge and Fuel Stains

    Float Bowl Removed
    Float Bowl Removed, Missing Paint on Emblem

    After Rebuild/Refinish

    Engine Side of Restored / Rebuilt Carburetor
    Engine Side of Restored / Rebuilt Carburetor

    Top Side of Restored / Rebuilt Carburetor
    Top Side of Restored / Rebuilt Carburetor

    Outlet Side of of Restored / Rebuilt Carburetor
    Outlet Side of of Restored / Rebuilt Carburetor

    Carburetor Mounted - Clean
    After-R100RS Type 94 Rebuilt and Refinished Carburetor

  2. #77
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    Quote Originally Posted by nevadaslim View Post
    Beautiful job on the carbs. How did you clean the body, tops and the bowls? Ultrasonic cleaner?
    Hi nevadaslim,

    No, no ultrasonic cleaner. I talk about how in the write-up. I also have this document on my web site that covers most of the techniques I use to refinish parts.

    51 BMW 1973 R75/5 Refinishing Techniques
    I hope that helps.

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

  3. #78
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    1983 R100RS Remove Camshaft and Crankshaft

    Folks,

    I remove the crankshaft to check the condition of the main bearings. In order to remove it, I have to remove the camshaft first. I use the tools I bought from Cycle Works to remove the crankshaft. I don't need all those shown below :-)

    Cycle Works Stage III Tools
    Cycle Works Stage III Tools

    I asked Matt Parkhouse, a long time airhead mechanic who lives about two hours from me, to assess the condition of the crankshaft main journals and the main bearings. He found the front bearing was serviceable but the rear main bearing was just outside the maximum clearance. He replaced the bearing and now the front and rear main bearing clearances are close.

    Measuring ID of Original Rear Main Bearing
    Measuring ID of Original Rear Main Bearing

    Since I have to heat the front of the engine block to 275 F, I removed the stater motor and crankcase vent housing hose so they would not be damaged.

    Here is the block with the crankshaft and camshaft removed.

    Engine Block Looks Empty
    Engine Block Looks Empty

    You can read about how I do this work here:


    And here is a short video of the highlights of the work:

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

  4. #79
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    Looking Good

    Looking Good, Brook. I just changed the cables on my RT and had to look up your pictures on how to do them. St.

  5. #80
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    Quote Originally Posted by STEVENRANKIN View Post
    Looking Good, Brook. I just changed the cables on my RT and had to look up your pictures on how to do them. St.
    Thanks Steve. More to come soon, I hope.

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

  6. #81
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    1983 R100RS Install Flywheel

    Folks,

    I show how I install the flywheel, aka, "clutch carrier". I also show how I prepare the flywheel before installation, including

    • Cleaning the guide ring,
    • Polishing out the grooves in the guide ring created by the rear main seal,
    • Dressing the teeth on the flywheel to remove ridges created by the starter motor gear engaging with them,
    • Replacing the large o-ring in the guide ring,
    • Cleaning the crankshaft bolt holes and bolts, and,
    • How to center the flywheel on the bolts so the ignition timing is correct.


    Bath Time For the Bell Housing and Flywheel with Engine Degreaser
    Bath Time For the Bell Housing and Flywheel (in Pan at Right) with Engine Degreaser

    [Cycle Works Front Bearing Carrier Puller Used To Push Crankshaft To Rear
    Cycle Works Front Bearing Carrier Puller Used To Push Crankshaft To Rear

    Flywheel Guide Ring-Note Grooves in Shiny Band From Cut By Rear Main Seal
    Flywheel Guide Ring-Note Grooves in Shiny Band From Cut By Rear Main Seal

    Grooves Are Gone After Polishing Them Out :-)
    Grooves Are Gone After Polishing Them Out :-)

    Bracing Engine Block Before Torquing Flywheel Bolts
    Bracing Engine Block Before Torquing Flywheel Bolts

    You can read about how I do this work here:


    I also shot a short video that summarizes the work.



    VIDEO: 1983 BMW R100RS Prepare and Install Flywheel

    I hope this is helpful to anyone planning to do this work.
    Brook Reams - Arvada, CO
    Endeavor to Persevere
    Various Two-wheeled Vices, All BMW || Website: Airhead Rebuild Projects
    2004 R1150-RS||2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  7. #82
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    1983 R100RS Install New Clutch

    Folks,

    After I installed the flywheel, I'm ready to install the clutch. You can see how I install the flywheel here:


    And, you can see how I removed the clutch here.


    I decided to install all new clutch parts rather than have them rebuilt by Southland Clutch. Here is a write-up showing how I install the clutch.


    And here is a summary video showing highlights of the installation procedure.


    VIDEO: 1983 BMW R100RS Install New Clutch

    The 1981+ model year clutch is a different design than was used on the earlier model years. You can see how to install the earlier style clutch here.

    21 BMW 1973 R75/5 Install New Clutch
    21 BMW 1977 R100RS Remove, Refurbish, Install Clutch

    Here are a couple pictures from the write-up.

    Clutch Centering Tool for 1981+ Clutches
    Clutch Centering Tool for 1981+ Clutches

    Clutch Assembly Parts
    Clutch Assembly Parts

    New Clutch Bolts with Washers
    New Clutch Bolts with Washers

    Verifying Clutch Plate Sleeve Is On Front Side of Clutch Front Cover
    Verifying The Sleeve Side Of The Clutch Plate Is On The Transmission Side of The Clutch Housing Cover

    Clutch Centering Tool Installed
    Clutch Centering Tool Installed

    Clutch Center Tool Removed - Clutch Is Installed
    Clutch Centering Tool Removed - Clutch Is Installed
    Brook Reams - Arvada, CO
    Endeavor to Persevere
    Various Two-wheeled Vices, All BMW || Website: Airhead Rebuild Projects
    2004 R1150-RS||2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  8. #83
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    1983 R100RS Install Crankshaft Sprocket, Nose Bearing, Timing Chain, Timing Cover

    Folks,

    I completed installing a new crankshaft timing sprocket, nose bearing, timing chain, chain tensioner and rubbing block, front main seal and the inner timing cover. So, a lot of progress made.

    New Parts-(Top) Timing Chain Sprocket, Nose Bearing; (Bottom) Single Row Timing Chain
    New Parts-(Top) Timing Chain Sprocket, Nose Bearing; (Bottom) Single Row Timing Chain

    Timing Chain Tensioner and Rubbing Block Parts
    Timing Chain Tensioner and Rubbing Block Parts

    New Front Main Seal
    New Front Main Seal

    Inner Timing Cover Gasket and (2) Doughnut Gaskets (Green Inside Red Circle)
    Inner Timing Cover Gasket and (2) Doughnut Gaskets (Green Inside Red Circle)

    Starting Point
    Starting Point

    Sprocket, Nose Bearing and Timing Chain Installed
    Sprocket, Nose Bearing and Timing Chain Installed

    Newly Painted Inner Timing Cover Installed
    Newly Painted Inner Timing Cover Installed

    This year engine uses the single row timing chain and comes with a master link which is very convenient. The older dual-row chains were continuous and I had to cut the chain to remove it which was a bit of a hassle.

    You can read about how I do this work here:


    I shot three short videos that summarize what I documented in the write-up.

    VIDEO: 1983 BMW R100RS Install Crankshaft Sprocket and Nose Bearing
    VIDEO: 1983 BMW R100RS Install Timing Chain
    VIDEO: 1983 BMW R100RS Install Inner Timing Cover

    If you have the older engine with dual-row timing chain, here are links to how I did the same work with the dual row chain. The procedure is pretty much the same. That said, the better method for removing the continuous dual-row chain is to use bolt cutters, not grind off two pins on a link, as that creates a lot of shrapnel that you have to clean up.

    Last edited by brook.reams; 01-20-2020 at 12:28 AM. Reason: Updated Inner Timing Cover Video
    Brook Reams - Arvada, CO
    Endeavor to Persevere
    Various Two-wheeled Vices, All BMW || Website: Airhead Rebuild Projects
    2004 R1150-RS||2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  9. #84
    Nick Kennedy
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    Brook
    Great job on these documentation write up's
    When you put that Master link on that timing chain that raised a red flag in my mind.
    Can you get a chain riveting tool in there? Is there not enough room?
    Those master links have a history of coming off.

  10. #85
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    Quote Originally Posted by nickrides View Post
    Brook
    Great job on these documentation write up's
    When you put that Master link on that timing chain that raised a red flag in my mind.
    Can you get a chain riveting tool in there? Is there not enough room?
    Those master links have a history of coming off.
    Hi nickrides,

    Well, the master link is original to this style chain. BMW discontinued the continuous chain when they made the chain a single row chain. I've heard no stories of that link going missing, so I do not believe it's a "weak link" (pun intended) in the design. :-)

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

  11. #86
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    1983 R100RS Install Euro MotoElectrics (EME) Type III 400 Watt Charging System

    I'm upgrading the charging system from the stock Bosch 240 watt alternator to the Euro MotoElectrics (EME) 400 watt, Type III charging system. This alternator uses the same design as the Bosch one with an electromagnetic rotor with brushes.

    EME Type III 400 Watt Kit Components
    EME Type III 400 Watt Kit Components

    I also decided to replace the stator cover, part# BOALT-StatFram107Plus and also replaced the battery (+) cable and the voltage regulator sub-harness. EME provides two cable kits: one has the battery (+) and (-) cables, part# BCK-475216 and the other has the voltage regulator and the charging system wires that connect to the diode board, part# BOALT-HAR80. The kit has some of the same wires included in the Type III charging system kit and is for the R80. But the voltage regulator sub-harness is the same as the one used on the R100 and the R80 kit is less expensive than the R100 kit as it has fewer wires.

    EME 107 mm Complete Stator Housing
    EME 107 mm Complete Stator Housing

    EME Battery (+) Cable
    EME Battery (+) Cable

    EMC BOALT-HAR80 Wiring Kit
    EMC BOALT-HAR80 Wiring Kit

    Here is what the completed installation looks like.

    Charging System Installed On Inner Timing Cover
    EME 400 Watt Charging System Installed On Inner Timing Cover

    I documented the procedure here.

    I also made a video summarizing the procedure and posted it to my YouTube channel.


    VIDEO: 1983 BMW R100RS Install Euro MotoElectrics 400 Watt Charging System
    Last edited by brook.reams; 02-08-2020 at 09:22 PM.
    Brook Reams - Arvada, CO
    Endeavor to Persevere
    Various Two-wheeled Vices, All BMW || Website: Airhead Rebuild Projects
    2004 R1150-RS||2002 F650-GS||1983 R100RS||1977 R100RS||1973 R75/5

  12. #87
    Registered User Rinty's Avatar
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    Nice!

    Pardon my ignorance Brooke, but did you triple ground the diode board? That was a mod that I had done to my '82 RS (at least, I think it was the diode board).
    Rinty

  13. #88
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    Quote Originally Posted by Rinty View Post
    Nice!

    Pardon my ignorance Brook, but did you triple ground the diode board? That was a mod that I had done to my '82 RS (at least, I think it was the diode board).
    Hi Rinty,

    In a word, NO.

    But, you can see what I did do below.

    Ground Wire Octopus Installed and 2 Stock BMW Ground Wires Installed
    Ground Wire Octopus Installed and 2 Stock BMW Ground Wires Installed

    I think this adds new meaning to "belt and suspenders" and maybe more like "belt, suspenders and velcro"

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

  14. #89
    Registered User m_stock10506's Avatar
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    You really do a great job documenting your upgrades and rebuilds. You’re gonna regret soldering the brushes into place. The brushes with eyelet terminals are a few minutes to replace when the brushes wear down. Great write up, photos, and videos Brook. Thanks.
    Michael Stock, Trinity, NC
    R1100RT, R100, R60/6

  15. #90
    B Reams brook.reams's Avatar
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    Quote Originally Posted by m_stock10506 View Post
    You really do a great job documenting your upgrades and rebuilds. You’re gonna regret soldering the brushes into place. The brushes with eyelet terminals are a few minutes to replace when the brushes wear down. Great write up, photos, and videos Brook. Thanks.
    Hi Michael,

    Well, I didn't solder the brushes as they are the ring terminal kind and come assembled on the new stator cover. On an earlier build for the 1977 RS, I wasn't aware of these and did solder them.

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

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