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Very Hot Topic (More than 25 Replies) I thought I should stop procrastinating (Read 3575 times)
Tony Smith
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I thought I should stop procrastinating
09/08/13 at 03:15:02
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Ah electrics, don't you just love them. Disconnected the coil and hooked up a 5amp 12 volt power supply and "proved' most of the circuits, which gave me some incentive to start re-fitting electrical bits. 

Please note that I am in awe of the quality restoration work being done by some here - My 65 just has to work, don't really care about looks.

That's my excuse....

  

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1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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quixotic
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Re: I thought I should stop procrastinating
Reply #1 - 09/08/13 at 16:08:03
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Looks like a fun project...but please re-size and rotate the next bundle of photos.
  

1979 R65 with 20,000 orig km's
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Tony Smith
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Re: I thought I should stop procrastinating
Reply #2 - 09/08/13 at 21:58:56
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quixotic wrote on 09/08/13 at 16:08:03:
Looks like a fun project...but please re-size and rotate the next bundle of photos.



Oops....Sorry will do.

in the meantime I'll stick to what I know. Here is a link to the project
http://tinyurl.com/kvfjfum
  

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Re: I thought I should stop procrastinating
Reply #3 - 09/09/13 at 07:27:15
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Just as long as it is safe and reliable, it's your ride, enjoy Smiley D2
  
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Re: I thought I should stop procrastinating
Reply #4 - 09/09/13 at 08:34:48
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That piston has seen better days.  How did that happen?
  

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Re: I thought I should stop procrastinating
Reply #5 - 09/09/13 at 10:18:45
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quixotic wrote on 09/08/13 at 16:08:03:
Looks like a fun project...but please re-size and rotate the next bundle of photos.


Excellent idea for your initially posted pics, too.

Thanks, Quixotic  Smiley
  

Monte Miller
Denton, TEXAS
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1981 BMW R65
1983 BMW R65
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Tony Smith
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Re: I thought I should stop procrastinating
Reply #6 - 09/09/13 at 15:17:59
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quixotic wrote on 09/09/13 at 08:34:48:
That piston has seen better days.  How did that happen?


In early 1994 and at 9 years of age and around 60,000km and having never had the heads off, the original owner (who was as deaf as a post) was riding home when it "lost power". He rode it home (a further 15km) and then discovered the awful truth. Needless to say the head and barrel were also thoroughly destroyed

  

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Tony Smith
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Re: I thought I should stop procrastinating
Reply #7 - 05/18/14 at 19:34:48
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Well, this last weekend I thought I should stop procrastinating and do some work on the R65. After all I hand out advice with gay abandon to others so I thought it might be time to practice what I preach.

First item on the agenda was to pull the pots off, the right one I pulled off 20 years ago and removed the piston (photos of a well destroyed piston have featured here previously) and conrod (to check for being bent). The left side has never been off.

To be honest I have been dreading looking inside as I could not remember doing anything in particular to preserve the engine as 20 years ago I regarded it as "buggered" and had no plans to ever put it back together.

To my very great relief I was more conscientious 20 years ago than I remembered, not only was the crank journal covered in a thick smear of grease I had put a pot of "conformal" vapor barrier inside the now empty pot. The conformal has done its job well, not only was the crank in perfect condition and after removing the grease and applying assembly lubrication I put the conrod back on, there was no corrosion on the exposed cam lobes, the cam followers all came out easily (and were assembly lubed and replaced, even the rocker gear worked smoothly and has no corrosion on them. RESULT!

Then came my first annoyance. I grabbed the head I bought from an eBay shyster and looked at it for the first time. This head was sold to me as a 1982 r65 cylinder head, As soon as I turned it over to look at the valves I realized that it is a R45 head.

BTW, if anyone here has need of a RHS  R45 head with 32/34 valves it is yours for the price of postage.

In the medium term I have a set of 1980 small valve 34/38 heads for which I also have brand new valves. These will be going on to the 1979 cylinders and pistons I also already have.

In the longer term, if I keep the R65, when it needs a refresh I will buy a RHS late model head 40/36 and a RHS Nickasil pot and (hopefully) one good std weight piston and give the old girl a bit of a performance lift.

I guess that in the short term I may also going to need to buy needles and jets to downgrade the carbs, although as there was only 5hp difference between the small valve and big valve heads I may not need to.

I also finished the electrics, all that I need do now is fit a JPT plug to the ATU to replace the one I broke 20 years ago (failed to observe the wire bale and forced it apart) and it will be ready to run as soon as the heads come back from the machine shop.

Brake wise I am initially fitting a single Brembo caliper, I have as a longer term project acquired a pair of Brembo 4-pot calipers from an R1100 and I will eventually fit those once I decide of I am going to mill the calipers, the forks or both to regain the correct spacing.

Target is to have the thing running and registered by the end  of June as I am getting sick of not having something to ride capable of highway speeds.
  

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Tony Smith
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Re: I thought I should stop procrastinating
Reply #8 - 06/16/14 at 17:33:46
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A quick update....

The small valve heads and the iron barrels went to the local machine shop two weeks ago with instructions to k-line all guides, fit the new exhaust valves I supplied and do a 3 angle re-seat on the valves, and finally to vapor blast everything to clean it up.

I got a phone call from them mid last week to say that one iof the inlet guides was loose, I said to drive it out, knurl the guide bore and then drive it back in, the proprietor, who I've known for years, said that was a bit rough even for me and didn't want to do that. OK, I said, fit a guide from something automotive, to which he replied that the R65 has a valve guide size not remotely like anything he had in stock, or which he could order in at short notice.

On to Motobins.

At first I wasn't too unhappy when I saw that their "pattern" valve guides were only GBP 7.00 each. Then I saw that the "pattern" guides only come in standard size and that to get an O/S guide I was goign to be buying genuine and at GPB19.50, that hurt. Over $40 Australian Pacific Pesos plus a further $15 for priority mail.

Ouch!

Hopefully they will be here tomorrow and I can finish engine re-assembly this weekend and see if it runs.....
  

1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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Re: I thought I should stop procrastinating
Reply #9 - 06/17/14 at 20:54:34
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At least it's only one seat.  Probably money well spent as the valves/seats are the weakest part of the engine.

Best of luck getting her to fire up this weekend!
  

'82 R65LS  "Heidi"

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Re: I thought I should stop procrastinating
Reply #10 - 06/18/14 at 15:42:48
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Thanks for that. No chance of it running this weekend, the guide has not arrived yet. But my three have! I ended up going with Pirelli "city demons" for two reasons.

Firstly I could actually buy a front and rear in Australia without having to wait for a ship to arrive (although I did have to buy from different shops).

Secondly I recently spent a weekend on a Royal Enfield GT shod with those three and was impressed with them.

I really wanted Conti-Go's but the next to arrive shipment is pre-sold and I would have to wait until September. The problem is, as I am sure many here know, that time has passed the R65 by and it now bears a "rare" tyre size..

Still I am on the downhill run now, I have everything I need to put it back on the road. I really wish I had made some better decisions earlier on as now as soon as the KLE is run king I will need to do a frame-off tear-down to fix the cosmetics.
  

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Re: I thought I should stop procrastinating
Reply #11 - 06/18/14 at 19:23:23
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What were your impressions of the RE GT? Rather sporty looking it is.
  

Monte Miller
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1983 BMW R65
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1986 VW Cabriolet
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Tony Smith
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Re: I thought I should stop procrastinating
Reply #12 - 06/18/14 at 20:56:08
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montmil wrote on 06/18/14 at 19:23:23:
What were your impressions of the RE GT? Rather sporty looking it is.


To put it bluntly, I am in love.....

The GT is never going to set the world on fire power wise, in fact I suspect my 30 year old Yamaha XT350 would effortlessly show it a clean set of heels in a straight line.

BUT. It has "enough" power to cruise comfortably at legal speeds (about 70 of your miles per hour on the open highway), has excellent brakes and pin sharp handling.

Ah, the handling....I am nearly 60 and I gave up trying too hard years ago. I went south to visit my terminally ill mother and my sister organized the GT fro me so that the two of us could go for a ride, something we used to do a bit of 30 years ago when we lived in the same town.

Mostly around the Blackall ranges north of Brisbane, lovely territory for riding an accurately handling bike.

Now I cannot claim to keep up with my sister on her Ducati 916 (she has "You just got passed by a girl - get over it!" emblazoned on the back of her leathers), but we were moving at a sufficient clip so that we came across several squadrons of weekend warriors, Lawyers, Accountants and the like out on their Litre plus Japanese sports bikes and I was truly astonished how easily the GT rounded a lot of them up, particularly going down hills.

The only problems I have with the GT are:-

  • The tank is much smaller than it looks and there is only around 200km (about 120 miles) in it
    • There is a stupid electrical cutout on the side stand so that the engine will not start if the stand is down and if you put the stand down with the engine running - it stops.
      • Every time you park anywhere, you have to beat the gawkers off (actually it is incredible how much attention it got).


      Would I own one? In a heartbeat.

      In fact next year once I've done the scrap heap challenge  (sort of an Iron Butt rally but limited by the honour system to bikes that cost less than $AU1,000 to buy and prepare for the rally) next year on the KLE 500 I bought recently I will probably buy a GT after selling the KLE.

      Some observations based on money that the owner of the bike I borrowed had spent fairly wisely.

      There is an alternate "sport" exhaust system, which has a nice "English" bark to it - worth every cent of the $250 cost as it sounds so much better than the stock item. (and who cares if it really improves performance or not!).

      The dual seat is a $280 cost in addition to the single "cafe racer" seat supplied. The dual seat is long, wide and comfortable, the cafe racer seat is not, in fact I went around the block on it and asked the owner if I could swap them back.

      That's it, all in all a really enjoyable motorcycle.
  

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Re: I thought I should stop procrastinating
Reply #13 - 06/19/14 at 07:27:15
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Thanks, Tony.  Your short review is better than some I've read in "real" motorcycle pubs. Smiley


Update: OK, since it was Tony that segued into Royal Enfield within his own thread, I really not hijacking his thread. This email newsletter item about the new RE GT, from Motorcycle Classics magazine, just now popped into my mailbox:

http://www.motorcycleclassics.com/continental-gt.aspx?newsletter=1&utm_source=Sa...
  

Monte Miller
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1981 BMW R65
1983 BMW R65
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1986 VW Cabriolet
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Tony Smith
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Re: I thought I should stop procrastinating
Reply #14 - 06/25/14 at 18:35:35
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Just to return this to something vaguely about R65s.

The engineering shop has just rung and my heads and barrels will be ready for collection at 5:00 today Yay!

Guess what I am doing this weekend?

The old girl will fire up for the first time in 20 years this weekend.
  

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Re: I thought I should stop procrastinating
Reply #15 - 06/25/14 at 20:08:14
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Tony did you replace the headlight and bezel? If so what are you running?
  
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Re: I thought I should stop procrastinating
Reply #16 - 06/25/14 at 22:41:24
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Quote:
Tony did you replace the headlight and bezel? If so what are you running?


I am still trying to locate a "proper" headlight to fit into the standard bucket and bezel, although I am forced to admit that the search is not going well.

In the interim I have fitted a very cheap and nasty light from ebay - see the photos on the google+ link in one of my earlier posts.

If I cannot find a automotive light to fit the BMW bezel I will with some reluctance fit the complete headlight assembly from a Yamaha XS750. This has the advantage of accepting a standard auto semi-sealed lamp, but I am reluctant to use it as I am on the scout for an XS750/850 to restore and I can feel in my water that if I use the headlight I have hoarded all these years, inevitably the restoration candidate will need one as well.
  

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Re: I thought I should stop procrastinating
Reply #17 - 07/24/14 at 21:56:14
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I have finally picked my heads and barrels up. Yay.

So why, when I posted I was picking them up on 26 June did it take so long? Well, there is a tale......

When I first decided to rebuild the R65 back in 2013 my thoughts turned to cylinder heads and barrels as my RHS head and barrel were cactus after dropping a valve.
 
After searching the world for a singleton head and barrel I ended up buying a set of "small valve" heads from Steve Hawsley "Boxerman" in the UK (and Barrels/Pistons from the USA). Steve told me that they were small valve heads that he had acquired for unknown or forgotten reasons and that I should look over them carefully before using. 

Pity I didn't follow good advice.

I simply matched the casting number to the right valves and ordered them from motobins. When they arrived I gave them to a local engineering firm in whom I have faith - they took one look as said "two weeks in the washer and then we will look at them.

The first drama was that they identified a loose valve guide - back to Moto bins for an oversized guide. I am particularly dirty on the topic of the O/S guide as not only was it bloody expensive, it was also very, very tight, in fact it would have been a valve drop waiting to happen - as all the other guides were being k-lined, it got the same treatment and was reamed to the correct running clearance.

But I am getting ahead of myself. The shop rang and said that the valves I supplied were the wrong ones. I went, had a look and sure enough the heads were fitted with the bigger valves. But how was this so given the casting numbers?

Well after they came out of the washing machine, the heads show the result of someone spending a lot of money on someone with a porting tool and flow bench, somewhere along the line they also paid to have the bigger valves fitted, Yay me!.

Photos of my ported and polished R65 heads tonight if I can resist slamming them on the engine and going for a ride that is....
  

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Re: I thought I should stop procrastinating
Reply #18 - 08/02/14 at 21:39:45
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Well, the sump is off for investigation and cleaning.

I do apologize for the very crappy photos, I used a very old Panasonic camera that I am sure in better (steadier) hands can take excellent photos, me, I've become reliant on the electronic trickery of more modern digitals....

Anyway, no real surprise as to the contents of the sump, i expected to find "nuggets" of alloy and that is what I found. I have already had the conrods out so I know that the aluminium filings didn't get past the screen and filter, the sump screen is a disgusting mess (more on that in a minute) and the filter is well speckled with fine alloy "sand".

The big surprise was the discovery that the PO cracked the sump and had it welded (badly). It obviously still leaked so he smeared the inside with black RTV, the pump screen is more than a bit chocked with the insidious stuff, had the valve not dropped I suspect that in a short time it would have died of lubrication failure.

RTV in small quantities is a fantastic thing, "sausages" of RTV loose inside your engine are not!.

  

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Re: I thought I should stop procrastinating
Reply #19 - 08/03/14 at 05:22:39
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Here is a much better picture of the cleaned up sump.

The RTV remaining in the base of the sump is fully cured, in fact it has been immersed in oil for at least 20 years and has 100% adhesion at the edges. I've canceled the rushed plan to buy a new sump and this one is going back on tomorrow.

The mistake made by the PO was to use RTV as a gasket and to use too much of it.

  

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Re: I thought I should stop procrastinating
Reply #20 - 08/09/14 at 03:26:09
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Well not too much procrastinating today.

Pistons, barrels and heads on today. And last job, timing cover off so I can clean up the end of the crank and replace the outrigger bearing.

I reckon i will hear it run tomorrow. got to sort the electrics under the front cover and put a new plug on the ATU.

First job tomorrow,  to give my back a rest, clean up the carbs and put a rebuild kit through them.

  

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Re: I thought I should stop procrastinating
Reply #21 - 08/09/14 at 08:02:39
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Closer and closer...  Wink

  

Monte Miller
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Re: I thought I should stop procrastinating
Reply #22 - 08/09/14 at 11:53:34
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Look at those lovely valves!  I hope your camera will take video.  I'd love to hear them tick along.

RTV can be really nasty stuff.  If it were me I'd rip it out and re-seal the pan using lead.
  

'82 R65LS  "Heidi"

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Re: I thought I should stop procrastinating
Reply #23 - 08/09/14 at 18:00:13
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montmil wrote on 08/09/14 at 08:02:39:
Closer and closer...  Wink



Yes you are right. Had i realized what was required 18 months ago what I started I would have done things very differently, for instance in retrospect I wish i had completely dismantled it and sent the frame and swing-arm out for bead blasting and that I had all the allow soda blasted.

I wish that because the mechanical side of standing the old girl up has taken so much longer (and cost so much more) than I thought it would and in a few days time I am going to have a mechanically sound R65 that frankly looks like a bag of shite.

This was supposed to be an interim thing whilst I give the R100 a much overdue refit - instead it has turned into its own saga.

The "moral" of the story is that if you set out to get a motorcycle running, that last ran 20 years ago, and which had mechanical faults when it was parked, and which has been used as a Christmas tree for parts - well then you are in a world of hurt.

Doubtless I will feel more kindly disposed towards it in the next few days......
  

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Re: I thought I should stop procrastinating
Reply #24 - 08/09/14 at 18:09:14
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Luca wrote on 08/09/14 at 11:53:34:
Look at those lovely valves!  I hope your camera will take video.  I'd love to hear them tick along.


I am planning to "GoPro" the successful first start - that is to say that the footage of the less than successful starts, along with the swearing, will remain private.  Smileyhttp://www.bmwr65.org/htdocs/yabbfiles/Templates/Forum/default/smiley.gif


Luca wrote on 08/09/14 at 11:53:34:
RTV can be really nasty stuff.  If it were me I'd rip it out and re-seal the pan using lead.


I could not agree more and the PO's usage of the be-dammed stuff instead of gaskets was within an ace of destroying the engine well before it dropped a valve. The oil screen was very near clogged with RTV "sausages" that resulted from wet RTC being squeezed out joint lines.

RTV can be used instead of gaskets, the secret is to use bugger all and let it dry before mating up.

However, in the case of it being used to fill the cracks in the sump, I'm happy to leave it there - it isn't going anywhere and has been immersed for 20 years. I will buy a 2nd hand sump in due course and swap them over on a maintenance day.

I had grand plans of putting in another big day today but I have caught a bug and spent most of last night with a temperature through the roof and shivering under multiple blankets, oddly enough, my lovely partner has it too and she is normally bug proof (as in no self respecting bug would dare to bite HER), so we are both feeling like crap, I will try and do the carbs this afternoon.
  

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Re: I thought I should stop procrastinating
Reply #25 - 08/18/14 at 02:20:20
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Well my three day weekend is over and courtesy of the moronic Previous Owner I still haven't fired it up. I have a lengthy rant in the appropriate part of this board detailing how a weekend was lost undoing the idiocy he bequeathed me with.

And courtesy of our Government postal service I haven't got fork seals so i can't put a front wheel under the thing yet either.

Truthfully, unless I discover something else the MPO ("moronic previous owner") has left me with, its a case of hanging the carbs, connect temporary fuel supply, put in a battery, crank it with the coils disconnected until it oils up and then reconnect the coils and hit the button.


I thought I had some high temp insulation wire, but I can't find it so I used the old lead on the beancan, the keen eyes will see that it has cracked where it enters the can. I will use this one to get the bike running and for a few weeks with no major journeys. Courtesy of another member of R65.org I have a dead beancan to repair using on the the Siemens hall effect devices I have in stock. The MPO had it fill choc-a-bloc with wheel bearing grease, not wonder it was a bit stiff to turn over.

Also please note the lovely Junior Power Timer plug added by me today.

The other thing I did - I found the data plate, this made me very happy as whilst I could still register the bike without it fitted, it would have been a long and tedious argument with Public Servants and that is my second least favorite way of spending my time. Feb 1984 is the construction date, dunno why I thought it was 1985.

Qther things done this weekend:-


  • fitted new cone coupler vibration mounts (see rant for further discussion of the MPO)

    Mounted up alternator and started proving the wiring.

    Re-fitted exhaust system (now it is starting to look like a motorcycle again)


In court doing my day job for 3 or 4 days this week so I'm not going to get near it again till next weekend.

As Monte said "Closer, ever closer".


  

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Chris S
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Re: I thought I should stop procrastinating
Reply #26 - 08/19/14 at 04:01:01
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"Had i realized what was required 18 months ago what I started I would have done things very differently".
----------------------------------------------------------------------

For what it's worth Tony, I kick myself frequently over the mistakes I have made with my resto. In fairness, life has dealt some cruel blows over the last three years, but I so wish I had thought mine through a little better.

I don't have the knowledge or expertise of most on this forum, but I sure have made my job a lot harder!!!!!

The key thing is to learn from the mistakes we make and just get on with it. I look forward to finishing mine over the next 6 months or so (with a little help from others... Kiss).

I enjoy reading your posts and look forward to seeing the results of all your hard work.

Heads down gents and on with the work...
  

1981 R65
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Re: I thought I should stop procrastinating
Reply #27 - 08/19/14 at 23:40:00
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Wow mate - one heck of a journey but some great picks. I hope it all works out fine for you and you're back riding it soon  Wink
  

1984 R65 (860)
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Re: I thought I should stop procrastinating
Reply #28 - 09/19/14 at 23:28:53
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It is a RUNNER!

Well for the first weekend in the last month i haven't had my mother in hospital with life threatening DVTs, my Father hasn't had another heart attack and our lovely old blue dog seems to have postponed her own shuffle into the quire eternal.


So, I actually got some work done.

Last weekend i discovered the starter motor was a bit sick and the sum total of my work was to re-condition it - fortunately a Bosch starter is a Bosch starter,  I had a good Pull in solenoid and a set of brushes dating back to my VW days, so the starter is now in fine fettle.

First thing I did today after testing it was to pull the spark-plugs out and take off the rocker covers and crank the engine until it was well oiled up. It took about 2 minutes in total before I was satisfied with the oiling to the rockers (LHS intake was the last to come up and I was in fact at the point of starting to pull stuff apart to find out why).

After oiling, I connected up a fuel source, refitted the spark-plugs and "went for it".

I had a bottle of ether on hand ready to give it some help, but to my utter and complete amazement  the magnificent old thing fired on about the third rotation and started running.

A bit smoky, but then I was using mower fuel. The LHS carb flooded so I'd best be finding out what is going on there.

I'm enthusiastic enough now to put the front suspension in, fit the brakes, rebuild the fuel ta and fill the tank - looking to ride it around the suburb tomorrow.

The little red assistant is Rosie the red cattle dog. She has taken an intense dislike to the R65 and was barking and biting it. I think because I have spent so much time that in her view should have been used for dog walking purposes of the past few months.


https://www.youtube.com/watch?v=kjQo0W_4i4M




  

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Re: I thought I should stop procrastinating
Reply #29 - 09/20/14 at 07:35:03
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BRAVO!!!

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

'82 R65LS  "Heidi"

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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.
  

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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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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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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!



  

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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!
  

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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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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.
  

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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.

  

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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
  

Buzzing along on my tubeless 82 R65
Industrial mobile equipment Mechanic  for over 35years  
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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.

  

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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.
  

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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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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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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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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
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Re: I thought I should stop procrastinating
Reply #45 - 10/13/14 at 17:44:00
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montmil wrote on 10/13/14 at 08:37:56:
Check those problematic OEM fuses?


Oh how I wish it were that simple.
The fuses are intact and the terminals are even moderately clean. I do have mini circuit breakers on order from China, when they arrive and are installed I will post photos. My thinking is that I have a wire(s) parted within the main harness itself. I am hoping that is not the case and am further hoping for a flash of insight as to what the problem might be.

My heading off yesterday without putting the screws back in the vacuum ports is further and redundant proof that I am not immune to doing dumb things.

Simple solution is that I will put a few hours aside this coming weekend and will trace the wiring through (that is after I recheck the bulbs themselves and the bulb sockets of course).http://www.bmwr65.org/htdocs/yabbfiles/Templates/Forum/default/smiley.gif
  

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Re: I thought I should stop procrastinating
Reply #46 - 10/13/14 at 17:50:05
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MichaelSydney wrote on 10/13/14 at 06:36:27:
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


Thank you. But wash your mouth out..... There has been an awful lot of work and a lot of money tipped into the old girl. I regret even more keenly now that I did not strip the frame and have it and a stack of other parts blasted and repainted. Still I will do that next year once the KLE is up and running.

Meantime, aside from the electrical problems I whinged about in my earlier post, the only things I want to do before setting out at Christmas time is a new clutch, crank main seal and new final drive main seal. I have the main seal and I just received a final drive "kit" from motobins. I'll order a clutch plate later today and take a punt that the pressure diaphragm is OK (I was just so amazed that it freed up as easily as it did yesterday. I put it in gear, pulled the clutch in and verifed that it had not disengaged, I pushed back intendign simply to unload the gearbox so that I could change into neutral and it freed up.


MichaelSydney wrote on 10/13/14 at 06:36:27:
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.



well it runs.....That is a major difference.
  

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READY FOR ROADWORTHY TEST AND REGISTRATION
Reply #47 - 10/18/14 at 20:49:56
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Technically I should put the final drive seal kit through it, but the oil level is now so low in the final drive that it will not leak during the test. I am loathe to use the seal kit as I have a 32/10 final drive somewhere between the USA and here and I'd prefer to wait until it arrives and then use the kit on it if needed.

The final electrical problems where (for the benefit of anyone interested), no tail or brake light, and only the left front blinker was working.

Prior preliminary testing indicated that there was power to the brake light switches, the blinker relay and to the harness socket leading to the rear lights.

The blinker relay was marked with a GMH (General Motors Holden, a semi-indigenous auto manufacturer about to cease production). I could not remember if it was fitted when i bought the R65 or if i had swapped it out, for that matter I couldn't remember if the blinkers were working when I bought the bike - that was not a priority at the time.

I bought a new after-market blinker relay, just in case I paid extra for one that will work with LED lights - sadly i still had exatly one working blinker, although when I selected right blinker the relay made some rather horrid noises.

Because the job looked easier, I switched at this point to the tail/brake lights. I cleaned the terminals, taking the opportunity to fit the "innards" from the better condition tail light I bought form Germany. I also tested the power connecters back to the plug and socket at the front of the sub-frame and in the process discovered a lot of corrosion on the earth connector.

Cleaned that up and I had tail and brake lights.

Still no blinkers, pulled all the blinkers apart, cleaned the lamp connectors, replaced one lamp that looked dodgy and put back together. Yay, had LHS blinkers, but the RHS blinked once and then the relay resumed making horrid noises.


Penny dropped. Took handlebar switch off and blasted with contact cleaner, followed by CRC. all blinkers now work.


Wired a 4" LED light strip to the parking circuit and fitted below headlight.


Job done. refitted tool trays so I can carry tools and multimeter. Rang friend and by the time anyone reads this I will be off on a 100km test ride.

Let you know how that goes on return.
  

1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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Tony Smith
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Well it survived a 130km ride.
Reply #48 - 10/19/14 at 00:50:57
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Only snag was the RHS carb had a little piddle, fixed int he usual way.

Sadly it will not be registered tomorrow, I had hoped that a few good applications of the front brake would sufficiently free the brake pistons to move wrt to the seals. That didn't happen so I need a brembo rebuild before the roadworthy.

  

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 #49 - 10/27/14 at 15:25:03
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The fleet.

Still waiting for the Brembo seals - from the USA at $12.95 for the apparently rare 36mm calipers. The price beat the hell out if anything else around, particularly as the seller sensibly realizes that once he throws the new bolts and small tube of lubricant away (at my request) the rest fits nicely into a standard envelope and can be posted at letter rates.

Waiting, waiting..........


In the meantime I am riding it carefully to build up a few miles.


Lastly, a picture of our fleet of runners. Have a close look at the red bike - "one of these things is not like the other thing, one of these things is not the same". Ignoring the seating arrangement, and the twin discs, who can pick the major and significant difference between these two r65s?


  

P1070164.JPG ( 477 KB | Downloads )
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P1070166.JPG ( 472 KB | Downloads )
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1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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Adrian
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Re: I thought I should stop procrastinating
Reply #50 - 10/27/14 at 22:40:57
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Hnmmmmm - would it be the rocker covers by any chance  Wink
  

1984 R65 (860)
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Re: I thought I should stop procrastinating
Reply #51 - 10/28/14 at 01:09:39
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Adrian wrote on 10/27/14 at 22:40:57:
Hnmmmmm - would it be the rocker covers by any chance  Wink


In a word -no......The Repop peanut covers were a Christmas present to "her indoors" last year. I fail to see the fascination with peanut covers personally, other than (at least in the case of the ones I bought) they are a bit thicker than the "proper" ones and mask tappet noise a treat.

The difference is that the Red R65 was fitted with a 1985 R80 engine in 1987. If you look very carefully you will see that it is a bit wider than a "genuine" R65 (the black one). It used to be more obvious as the original R65 crash bars were still in place until late last year, the rocker covers were somewhat further outboard of the bars and they therefore were not going to do much in an accident. But after 26 years of me occasionally raising that point, herself relented and bought some R80 crash bars.

My R65 will become a "Frankenbike" itself late next year - I will use it to run the (by then) rebuilt R100 engine in.....Hmm... an R65 with a 1978 R100RS engine with 40mm Bings and pipes, 30 years ago that might have surprised a few people used to the  somewhat sedate performance of 1st generation R65s.
  

1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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Re: I thought I should stop procrastinating
Reply #52 - 11/09/14 at 23:31:00
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The R65 passed roadworthy inspection wit flying colours and is now registered.

The primary phase of the restoration is now complete. I will use the old girl for a few months and sort out any snarls that arise. Next winter i will pull it down to a bare frame and do back and do the cosmetics.

I have to admit that i felt rather chuffed with myself as I rode home from the registration office, in fact, more than a bit chuffed!

It's been a fun journey so far.......
  

1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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steve hawkins
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Re: I thought I should stop procrastinating
Reply #53 - 11/10/14 at 05:01:53
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Well done.  You ought to be chuffed.

Rev. Light
  

Steve Hawkins R100 (that wants to be an R65)
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Re: I thought I should stop procrastinating
Reply #54 - 12/14/14 at 05:42:51
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Well, the old girl has now done just over 400 miles since the substantive rebuild was completed, 273 of this miles were done today. Set out with friends mounted respectively on Triumph Tiger, Triumph Daytona (Hinckley) and a BMW F650GS. The r65 is nearly 7 times the combined age of the other three bikes....


Anyway, the ride consisted of a lovely mountain climb (Gillies range) followed by a run to Raveshoe, back to Herberton and Atherton, thence Malanda via Gentle Annie, Peeramon for lunch and then home via Yungaburra, Tolga, Mareeba - down the range at Kuranda.

I thought the R65 would have difficulty staying with the others in the twisties and sadly I was right, part of that was me but most of it is that modern bikes have great big wide low profile tyres for a reason.

On the plus side after getting a little bit of a caning, including a 30km run at around 80mph, the R65 used no appreciable oil and sounded just as sweet when it came home as when it left.


Now, about those cosmetics I ignored during the rebuild.........
  

1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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Re: I thought I should stop procrastinating
Reply #55 - 12/15/14 at 10:05:59
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I bet the others were trying a lot harder than they care to admit....

Rev Light
  

Steve Hawkins R100 (that wants to be an R65)
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Re: I thought I should stop procrastinating
Reply #56 - 12/15/14 at 20:54:02
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steve hawkins wrote on 12/15/14 at 10:05:59:
I bet the others were trying a lot harder than they care to admit....

Rev Light



Nah, they were cruising,  there was some altitude involved - we went through the highest town in queensland along the way. I suspect that fuel injected engines cope better with altitude than ones with carbs.
  

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