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Thread: Wrench therapy project bike - 96 r850r

  1. #1

    Wrench therapy project bike - 96 r850r

    I am the proud most recent owner of an r850r. It doesnít run, it has been sitting in the elements for some years (most recent inspection 2014) I just started the tear down and have started a list of items to replace. 49k miles, with stamps in the service booklet from Colorado and Virginia - it was well taken care of for the first half of itís life, at least.

    Iím posting to get some experienced input on what I should be replacing while I have it torn apart. The wear items, spark plugs, fuel filter, air filter, battery, brake pads, oil-transmission-brake fluids I already have ordered. I was able to replace the fluid in the final drive and it looked good. The transmission drain bolt is rounded off, so that might prove interesting. All the plugs appear to be over-torqued. :|

    The gas tank is rusted completely through in spots, and there is substantial corrosion around the fuel filler area. Rust isnít really too bad anywhere else, strangely. Iím guessing a tank bag was left on in the elements. Iíve ordered a used tank off eBay.

    Is the Poly-V belt an issue? The cam tensioner? I read in the previous thread about brake lines - that sounds wise. As much as I like to go, I might like stopping just a little bit more.

    Thank you ahead of time.

  2. #2
    Registered User
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    When I acquired my '97 R1100R with 32K miles I disassembled the bike intending to check/lube splined shaft. With the transmission and final drive removed I inspected the clutch friction disc and found that it was marginally within specs. I made an appointment with the BMW dealership and took both the trans. and FD to the shop to have all the seals replaced. The shop did the whole job in an hour.
    I bought a new clutch disc, throw-out bearing, alternator drive belt, and rear main engine seal (installed by myself). Also, I replaced the plastic fuel quick-disconnects with metal ones. It's also a good idea to replace wheel valve stems with metal ones.
    Anyway, the bike has 85K miles to this date.

  3. #3

    Metal stems

    Very nice. Thatís what Iím hoping for - a little TLC and some new parts and many years of service. (In addition to zen time in the garage.) My closest bmw bike shop I believe is a couple of hours away. There isnít a motorcycle dealer with a shop of any make in my town, though I know at least one place that will work on them.

  4. #4
    Registered User dieselyoda's Avatar
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    Take your time. If you need to ride now, get another bike. If you want to learn and build something of your own, take your time and enjoy the learning curve.
    1997 R1100RT, 1981 KZ 440 LTD, R80RT, R90/6 sidecar, K1100RS,1983 K100RS (Cafe now)

    ďThe major civilizing force in the world is not religion, it is sex.Ē

  5. #5
    Gerard jagarra's Avatar
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    An alternate number for the alternator belt is a Dayco 5040240, I found some on ebay, bought 2 for half the price from dealer. for 1. I believe it is used on a Hyundai. Units I bought were made in Canada.
    1994 R1100RS-(5/93)-,1974 R90/6 built 9/73,--1964 Triumph T100--1986 Honda XL600R

  6. #6
    Thank you.

  7. #7
    DSC_0360_c.jpg
    While waiting for various parts to arrive, I removed the fuel tank, which has a gallon or two of fuel the color of enchilada sauce. Fuel isn't pouring easily out of the hoses, so I'm rotating the tank around and the fuel is pouring out of random holes, along with bits of rust. I don't see a fuel filter or cutoff, so that isn't promising for the state of the carbs.

  8. #8
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    I presumed that you removed the side plate to inspect the fuel pump and fuel quantity sending unit. If the screen sock is still attached to the pump then that should have prevented most of the crud from contaminating the fuel system. Anyway, for peace of mind, I'd replace the fuel pump, U-tube connector, access cover O-ring, and vent/overflow lines. You may consider having your fuel injector nozzles serviced...project's starting to become expensive.

  9. #9
    ď...project becoming expensive...Ē My wife believes BMW is a acronym for ďBig Money WastedĒ.
    1999 Triumph Tiger, 1998 K1200RS, & 1994 R1100RS

  10. #10
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    A lot of the times these "builder bikes" are cheap to buy, expensive to rebuild and a ball to drive after you have paid your tuition to the "BMW University of Self Teaching".
    Luckily enough, there are professors on this site that will guide you along the way.
    If I my be so bold as to suggest, throw that tank and everything in it away. Get your replacement tank, make sure it is sanitary clean and replace the fuel pump and everything else inside with new components. It will be a little expensive, but in the long run you will be glad you did.
    Clean the throttle bodies, replace the fuel lines.
    Once you have taken care of the fuel system. See if it will fire and run. If it does, hooorayyy!!
    Next turn your attention to the electrical system. If the bike is running it should not be much of a problem, Take a close look at the Halls Sensor, replace it or rewire it.

  11. #11
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    I bought an 1100R about a year ago and it's been a great riding bike, good on you for saving one from a premature grave. I just finished building mine into a pseudo-scrambler so I have some miscellaneous take off items in good shape that I was going to re-home including a front spoke wheel, forks, fork bridge and triple tree, stock shocks, rear torsion bar, gauge bezel, oil coolers, brackets and fairings, rear seat and rear side fairings (black with white pinstriping).

    Someone already mentioned the hall effect sensor and I was fortunately given the same advice recently, I say fortunately because when I looked at it, the wiring was completely shot and it was only a matter of time before it left me by the side of the road. There's a member here, GSAddict, who rebuilds these to better than new, so if you need it message him and he will hook you up.

    I'm trying to think of anything else I ran into when I was doing mine. I bought the cam tensioner kit but I'm pretty sure mine has already been done - i still need to pull it apart and check it but I may be selling that also. I also got a Galfer stainless braided brake line kit - there are one or two other good brands that are mentioned on this forum if you look.

    Other than that, best of luck and enjoy!

  12. #12
    Registered User slime's Avatar
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    Quote Originally Posted by derrickstone View Post
    DSC_0360_c.jpg
    While waiting for various parts to arrive, I removed the fuel tank, which has a gallon or two of fuel the color of enchilada sauce. Fuel isn't pouring easily out of the hoses, so I'm rotating the tank around and the fuel is pouring out of random holes, along with bits of rust. I don't see a fuel filter or cutoff, so that isn't promising for the state of the carbs.
    Yikes! That looks like the one I just replace in my old Astro van. 25 year old fuel is really nasty. Fuel tanks for these bikes seem high priced, to me. I have a 97 850r that had 25,000 miles on it. It had been serviced, so I just replaced the tires and have been riding it. Now has 36,000 ish miles. Little things are starting to need attention, but nothing horrible. I replaced the oil sight glass ( broke the first one had to order another ) It will need brake lines at some point ( could replace them now, but am unemployed Covid ) Fork seal starting to weep. I've replaced both shocks for Wilburs ( couldn't pass up a deal ) Probably needs the splines checked, but I don't have the facilities do do that at this time. I'll figure it out. So far, I really like this bike. I'm happy with it as it sits and it's been very affordable to own.
    Ride fast, take chances.

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