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Very Hot Topic (More than 25 Replies) I thought I should stop procrastinating (Read 4869 times)
Tony Smith
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Re: I thought I should stop procrastinating
Reply #30 - 09/20/14 at 13:51:58
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Luca wrote on 09/20/14 at 07:35:03:
BRAVO!!!

Hopefully you just have a speck of something on the float needle or the float is just stuck on its pivot pin.

That is all it was. I took the bowl off and ran fuel through it whilst jiggling the floats and whatever ailed it cleared.

The old girl has a bit more "bark" than I remember R65s having. Given that the only departure from std is the ported heads I am putting it down to those. Very much looking forward to riding it as I've not had a road bike since I laid up the R100 thinking it would only take "a month or so" to get the R65 running.......??

I fitted the fork legs yesterday (the were originally fitted to my wife's 1979) they are a little bent so I spent time making sure they bend the same way (forwards). I have a few things to do today so I'll be happy if I get the front end in and the brakes in place at both ends.
  

1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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montmil
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Re: I thought I should stop procrastinating
Reply #31 - 09/21/14 at 12:15:58
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Tony Smith wrote on 09/20/14 at 13:51:58:
I fitted the fork legs yesterday ... they are a little bent ...


Oh My doG, Tony. That's much like a girlfriend telling you she's, "a little pregnant". Smiley

Too danged funny, Mate!

  

Monte Miller
Denton, TEXAS
1978 BMW R100S
1981 BMW R65
1983 BMW R65
1995 Triumph Trophy
1986 VW Cabriolet
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Tony Smith
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Re: I thought I should stop procrastinating
Reply #32 - 09/21/14 at 15:59:37
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montmil wrote on 09/21/14 at 12:15:58:
Oh My doG, Tony. That's much like a girlfriend telling you she's, "a little pregnant". Smiley

Too danged funny, Mate!




C'mon Monty, don't go all Catholic on me. The forks are about 3mm bent, I've adjusted them so that the bed points forward.

I've ridden and sometimes raced bikes with worse bends in the forks. The trick is to make sure that there is no adverse loading between them causing wear or (in really bad cases) binding, get that right and you need only worry about changes in the effective steering angle or trail. I am of the opinion that the approximately 5mm longer wheelbase will not be a concern.

If that proves to be incorrect, I have a set of straight R65 fork legs, they have better chrome than the ones I've used, unfortunately they have significant surface rust on the inside which would need to be cleaned and polished before they could be used.

Anyway, my list of things to do is getting shorter and shorter.




  

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1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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Tony Smith
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Re: I thought I should stop procrastinating
Reply #33 - 09/21/14 at 16:26:59
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Don't use Pyramid Parts fork seals. The dust seal is a fraction too small and it is therefore impossible to fit the buggers without the dust seal folding over and causing a lot of stiction.

As I run gaiters I have run a scalpel around the seals and removed the dist lip - i will swap them out after buying genuine seals. It's a pity as the Pyramid Part seals are cheap and they look to be good quality.


A quick follow up.
In the video of the first start there is footage of my red cattle dog Rosie getting a swift kick. She has developed a hatred of the r65, anyone who knows cattle dogs knows that they are noted fro developing obsessional, OCD behaviour that they will persist in, even if they are hurt doing it.

At the time Rose was biting the exhaust pipes and mufflers, I knew she was getting hurt because I could see "residue" on the headers, I had to break her attention span.

The problem however has solved itself. Yesterday when i was balancing up the carbs Rosie started attacking the R65 again, although this time she was keeping on the opposite side of the bike to me. As the pipes for hotter she started to loo for something else to bite - she selected the LHS spark plug cap.

When the inevitable happened you should have heard her yelp, she now walks around the r65 giving it an extremely wide berth as she has discovered that the big bad motorcycle bites back!



  

1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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Luca
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Re: I thought I should stop procrastinating
Reply #34 - 09/21/14 at 21:13:57
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I've also noticed that shepherds tend to go for two wheeled vehicles.  My family had an Aussie who was given to us after she bit the PO's ankle while he was rolling his beemer out of the garage.

P.S. I bet the R65 won't bark as loud once it's out of that reverberation chamber you've assembled it in!
  

'82 R65LS  "Heidi"

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Barry
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Re: I thought I should stop procrastinating
Reply #35 - 09/22/14 at 04:44:54
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My stanchions also seem to be bent.

Only by 1 or 2  thou but I've always adopted the same same procedure as Tony to get them as close to parallel as I can as far as the fork legs are concerned.

If you wanted to be pedantic and deal in fractions of a thou it's possible to argue there is no such thing as as dead straight stanchions just varying degrees of being bent.
  

Barry Cheshire, England 79 R45
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Tony Smith
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Re: I thought I should stop procrastinating
Reply #36 - 09/22/14 at 20:44:15
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Barry wrote on 09/22/14 at 04:44:54:
My stanchions also seem to be bent.

Only by 1 or 2  thou but I've always adopted the same same procedure as Tony to get them as close to parallel as I can as far as the fork legs are concerned.   


I don't have a press capable of bending the fork legs straight, the only one that I have access to belongs to the guy whose "porta-power" I borrowed a few weeks back to spread the frame enough to fit cone couplers, I decided to leave him alone.

The second reason is that it has been my past experience that straightening fork legs is not a fun job - in my case the bend is near uniform so I am simply going to ignore it. In the unlikely event that I have any strange handling "quirks" I will review that.
  

1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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Tony Smith
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Re: I thought I should stop procrastinating
Reply #37 - 09/29/14 at 21:59:42
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An update of sorts.

Front brake fitted and working - seen as an interim arrangement until I have time to engineer the Brembo 4pot calipers I bought recently so that they fit.

Rear brake fitted and as a result of looking in there, new shoes, seal and gasket ordered.

Electrics all but complete, just need to refit the horrid Chinese 
headlight I bought and rig up an LED parking light.

The only other major "to dos" are to fit the tap kit and then put the tap on the fuel tank, fit clutch and speedo cables and new shocks - she is then ready to ride. i am borrowing a dealer plate this coming weekend and hope to run up a couple of hundred kilometers to flush out any remaining snags - big assumption/hope in this - that the clutch that has not operated in 20 years can be freed and will still work without flying to pieces.

  

1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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Mrclubike
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Re: I thought I should stop procrastinating
Reply #38 - 10/05/14 at 21:23:30
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Tony Smith wrote on 08/18/14 at 02:20:20:


  • fitted new cone coupler vibration mounts  


What are these ?
Thanks Mark
  

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Tony Smith
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Re: I thought I should stop procrastinating
Reply #39 - 10/06/14 at 01:00:36
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Mrclubike wrote on 10/05/14 at 21:23:30:
Tony Smith wrote on 08/18/14 at 02:20:20:


  • fitted new cone coupler vibration mounts  


What are these ?
Thanks Mark


The R65 can (because not all do) suffer from annoying vibration. BMW instituted a "fix" which involves using cone couplers (rubber mounts) on the front engine mount and drastically reduced torque figures on the front mount (12ft/lb)

The jury is out as to whether they do much and frankly I will not be replacing these when they wear out, next time I will buy the standard spacers and solid mount the engine.

  

1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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Tony Smith
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Re: I thought I should stop procrastinating
Reply #40 - 10/06/14 at 01:09:34
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Bloody electrics....

15 minutes ago I got the battery charging circuit working on the R65, I have spent a total of 12 and a half hours on this, the only break being a 1.5 hour diversions to put the wife's bike back together after borrowing some bits.

I could not work out what was going wrong. A Bosch alternator is not rocket science, consisting of:-

A soft iron rotor with a coil wound into it so that excitation current will increase its magnetism and therefore the amount of power produced;

A pair of carbon brushes to impart excitation current to the rotor

A "wye" or "delta" wound stator coil in 3 part harmony.

A voltage regulator.

A bank of diodes to turn the AC power produced from all of the above into DC power that can be used to charge batteries etc.
 

and lastly, about 1/2 doz bits of wire that connect the major assemblies, stator, regulator and diode board together.


So simple as, but mine didn't work.

Lunch time Saturday I did the obvious, separate out all the individual components and test them individually (where possible). Long story short, everything tested fine and dandy, but it still didn't work.

The rotor (which is always the primary suspect because it is the only bit that "moves') tested just fine, besides I had a "gen failure" light which will not work unless current is passing through the regulator and the brushes and the rotor. The regulator is  a brand new purchase, so I grabbed a spare and fitted it - no charge. Ok that left the stator and the diodes.

Tested the stator, it was just fine. Tested the diode board and it came up with the right numbers, although a couple of times it seemed to take a long time to settle at the correct resistance, but the final figures were OK, so not the diode board.

Lastly I rechecked the wiring, no problem found. I did notice that the three phases were wired up in a different order to the wife's bike, I couldn't see that would make any difference, but i changed them anyway - no charge.

Then I remembered something critically important.

The alternator in the wife's R80 is actually out of the R65, I dimly remembered battling with her non-charging alternator and being unable to find anything wrong with it. Eventually I simply put the entire alternator, diode, regulator, wiring  package out of the r65 into it and it worked - case closed, although I had a vague memory of being suspicious of the wiring.

Of course I forgot all of that until I'd spent nearly 8 hours checking and re-checking stuff.


Now it occurred to me at this point that I had a fault that was "hiding" from me. It's difficult for wire to do that, it either works or it doesn't mostly (with rare exceptions), I knew it wasn't the regulator because I'd swapped it.

That left the diode board. I had a spare I'd bought along the journey of the last year, problem was it was a freebie throw in for the alternator i bought and the seller hadn't packed it well, it tested OK but the printed circuit board on the back was cracked and I really wouldn't trust it.

Which led me to pulling the diode board out of the R100.

Fitted it, cranked the engine and it started charging like a bought one.


So what is going on with the diode board I first used - which I now remember as coming off the wife's bike? I had a hunch and this time instead of mucking about with the minute current applied to the diodes by a multimeter I rigged up a test lamp consisting of an old Kombi headlight  - i wired the high and low beam in parallel to maximize the load.

There are of course six diodes on the diode board, they work in pairs to rectify the current coming from the 3 phases of the stator. As soon as i loaded up the middle pair the diode went open circuit which it should not have done. I waited 5 minutes and tested that diode with the meter and it firstly gave a "funny" indication, then tested perfectly - in both forwards and reverse current. Then i hooked up the test lamp again and it failed immediately.

What a b-a-s-t-a-r-d! Tests perfectly using test equipment and fails as soon as a real world load it put on it.

I am going to keep it and give it to someone I really dislike when they need a diode board.....

Well, glad that is over, but it has nicely stuff nearly two days of working on old BMW time for me.....


Got a few other things done, will post some photos tonight.
  

1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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Tony Smith
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Re: I thought I should stop procrastinating
Reply #41 - 10/06/14 at 03:12:44
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Just a few quick photos.


Firstly the ^&&^&*^&$ diode board with the "interesting" failure mode and then a couple of general shots showing stuff added since last weekend.


  

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1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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Tony Smith
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Well, I stopped procrastinating and took it for a ride
Reply #42 - 10/13/14 at 04:25:36
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I suddenly realized about lunchtime today that I had completed all the structural/functional checks and whilst there were still some electrical snags, there was no reason not to take it for a brief shakedown ride.

I runs smoothly, the gearbox is quiet and all gears are present and correct, the clutch freed up immediately, which is not bad after 20 years. Sadly after I adjusted the clutch arm there is no adjustment left, think I will plan on a new clutch plate before going touring at Christmas.

I have no rear lights or blinkers. i has tested the wiring back to the sub-frame plug and they are fine, likewise i have tested the brake switches and the blinker relay socket and they all show power available. Looks like I have some broken wires somewhere in the main harness - next weekend job that one!

A quite 5 miles around the suburb I live in is not a full practical test but it is enough to encourage me that this is going to be a good little bike.

On final laugh on me. Once it warmed up it was trying to idle at 2,500 rpm. I was a bit annoyed and when i got home I logged onto Motobins intending to order clutch plate, inlet trumpets and a new fuel tap (I broke the R65 tap and it is currently wearing one from the R100) when I had a sudden flash of insight. Tomorrow I'll put the vacuum port screws back in and I suspect that will solve the idle.

One other thing happened today that was seriously un-funny. I was finishing up the timing and carb balance when it suddenly went on 1 cylinder and started making "clappers of doom" type noises out of the RHS.  I initally thought maybe I had not bee so smart to reuse the that was attached to the piston that sucked the valve, but a quick listen convinced me it wasn't a small end noise - which left the head. I was having dire thoughts like a valve seat coming loose, but when I got the rocker cover off the problem was nothign other than I had not secured the exhaust valve tappet adjustment properly and it had backed out and I now had 1/4' valve lash rather than .20mm. Fixed that it sweetness was restored.

Finally, this is what the old tart looks like with nearly all its clothes on.

  

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1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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MichaelSydney
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Re: I thought I should stop procrastinating
Reply #43 - 10/13/14 at 06:36:27
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Well done! A good milestone in your progress, but the photos look very much like the ones you showed in post # 1 over 12 months ago!  Smiley

Nice to know that the old girl is so much healthier than when you started. Thanks for all the information in your thread so far.

  
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montmil
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Re: I thought I should stop procrastinating
Reply #44 - 10/13/14 at 08:37:56
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Check those problematic OEM fuses?
  

Monte Miller
Denton, TEXAS
1978 BMW R100S
1981 BMW R65
1983 BMW R65
1995 Triumph Trophy
1986 VW Cabriolet
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