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Julio A.
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Fork disassembly for dual shock R65.
06/21/14 at 03:20:43
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These Videos really helped me a lot when I had to open up my forks.
Its a complete disassembly video which will also explain each fork component, their function and proper reassembly sequence.

Part1:
https://www.youtube.com/watch?v=ymse3196ORY

Part2:
https://www.youtube.com/watch?v=WNHC00THAbw
  

Julio Alarcon
1981 R65
1976 R90/6
2001 R1150 GS/ADV
2015 TR650
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Kelvin
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Re: Fork disassembly for dual shock R65.
Reply #1 - 08/13/19 at 04:23:07
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A couple of notes, with thanks to all the contributors to threads on fork maintenance: I've recently rebuilt the forks on my R65LS relying substantially on this forum.

These two videos are indeed helpful. Although there are a number of BMW fork rebuild videos on youtube this was the only one I could find that dealt specifically with my LS forks. One caveat (apart from the need for a language warning): he uses an air wrench to remove the bolts at the base of the damper assembly. This works, but isn't necessary: a 13mm socket on two extensions (one long one short) down the staunchion will hold it while the bolt is undone. Same trick on reassembly allows correct torquing of the bolt and crush washer. He uses the air wrench again on assembly, and says that it doesn't matter if it's not correct because the bolt is held in place by the axel. This is technically correct, but if the bolt comes loose I'd expect fork oil to dribble past it, maybe onto the brake disks.

He installs the spring before the slider: you need to put the slider on first, and bolt the damper in place, before installing the spring.
  

1983 R65LS 1985 to 1988
1983 R65LS 1996 to present.
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ged in oz
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Re: Fork disassembly for dual shock R65.
Reply #2 - 08/13/19 at 06:29:33
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I used the Chris Harris guide as well when I did my forks a few months ago. He was particularly profane in that one! Actually, that level of cussing makes me feel good because I donít even swear that much while doing that sort of stuff!

Iíve been watching his gearbox spline greasing videos tonight because Iíve got that to do this week and he manages to get through the whole series of 4 videos and only drops the occasional Ďcrappity smackí. Smiley

What weight fork oil did you use? I used Castrol 10W and Iíve decided in the past week or so it needs something a little heavier.
  
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Tony Smith
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Re: Fork disassembly for dual shock R65.
Reply #3 - 08/14/19 at 00:38:08
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ged in oz wrote on 08/13/19 at 06:29:33:
What weight fork oil did you use? I used Castrol 10W and Iíve decided in the past week or so it needs something a little heavier.


You must have the leakiest damper rod pistons of all time. I weigh quite a lot and when I rebuilt the original R65 forks I started with 100% Castrol fork 10 and they were near rock solid. I backed off to 50/50 and eventually ended up at 60% 5wt and 40% 10 wt, but that was with all brand new damper rod piston rings.

The wife's R65 which gets tuned for me because she doesn't ride it hard enough to tell the difference is 50/50.

When I rebuilt the K100 forks I automatically went for 60/40 and it was too harsh - I've since adjusted twice and am now at 40/60 (10/5) and that is near enough

Now I am not for a moment saying that you shouldn't have fork10 in yours, but I suspect if you ever replace the rings you will get the mother or all surprises.
  

1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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ged in oz
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Re: Fork disassembly for dual shock R65.
Reply #4 - 08/14/19 at 03:49:12
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Tony Smith wrote on 08/14/19 at 00:38:08:
Now I am not for a moment saying that you shouldn't have fork10 in yours, but I suspect if you ever replace the rings you will get the mother or all surprises.


Hmm, thatís making sense... I actually went out to the shed last night before I posted that to check what oil I had put in it back in February, and I was surprised to find it was 10W. I had some half empty bottles of 7W still on the shelf but Iím 100% sure I put the Castrol 10W in it.

My poor old thing has come back a long way so I havenít really pushed it too hard most of the time to date and Iíve generally been riding it fairly sedately, but as it gets more sorted and Iím more comfortable with it, the speeds have been rising more and more lately and it is starting to show up the deficiencies. At legal speeds itís more than adequate, but push it beyond 120 klm/hr and the physics are starting to overwhelm its ability and I really need to sort that out. Itís not safe.

If I remember correctly, someone here did manage to point to a source of new damper washers a couple of months ago? Iíd better search back and find the thread I think... and after Iíve done that I might look at upgrading the rear (YSS) shocks as well.

  
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Tony Smith
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Re: Fork disassembly for dual shock R65.
Reply #5 - 08/14/19 at 04:26:43
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ged in oz wrote on 08/14/19 at 03:49:12:
[quote author=Tonysmithau link=1403338843/3#3 date=1565761088]


If I remember correctly, someone here did manage to point to a source of new damper washers a couple of months ago?




That would have been me.

The r65 damper piston rings are marked NLA, but they are EXACTLY the same as the damper rings fitted to /7 forks

Motobins Code: 29000    BMW: 31 42 1 232 059 and GBP2.50 each.  Total 6 required.

  

1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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Re: Fork disassembly for dual shock R65.
Reply #6 - 08/14/19 at 04:41:15
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Bugga! I just ordered up my latest list of bits for my spline lube/gearbox swap from MB last night. As soon as you get through the checkout with those guys, you find another bunch of bits that you need....

Thanks Tony.
  
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Kelvin
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Re: Fork disassembly for dual shock R65.
Reply #7 - 08/17/19 at 17:17:11
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I'm using Motul 7.5W oil. Also, since it all interacts:
  1. Michelin Pilot Activ 90/90 Front
  2. Michelin Pilot Activ 4.00 Rear
  3. 34 psi front and rear
  4. Ikon rear shocks
  5. Original Fork springs (495mm, spec is 490-502mm)
  6. ATGATT weight about 90kg

This seems to work well.
  

1983 R65LS 1985 to 1988
1983 R65LS 1996 to present.
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ged in oz
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Re: Fork disassembly for dual shock R65.
Reply #8 - 08/18/19 at 04:33:43
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Hmm, thanks for the feedback Kelvin. Iím running Pilot Activís as well, but  probably a little less air than that. Iím only about 80kg fully kitted up so itís interesting that your running 7.5W...

Iíve got some Motul 7.5 on the shelf so I might give that a run. Potentially, my issue is that the 10W is too heavy, combined with an ageing (2014), slightly under inflated front tyre, itís just a poor combination.

Thatís certainly an easier solution than replacing the damper rings, or at least worth trying before I go down that route.
  
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