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Very Hot Topic (More than 25 Replies) '82 R65LS Restoration (Read 1666 times)
marcmiller001
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'82 R65LS Restoration
03/10/17 at 09:16:30
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I purchased this 1982 R65LS last Fall (2016) and got it somewhat cleaned up to the condition you see here. My first goal was to learn about it - the maintenance, what has been done and what needs to be done - you know, all the ins and outs. The more I inspected, the more I noticed almost 35 years of age... some covered up damage, lots of dry rot and forks that likely were never really serviced much. It had been sitting awhile and while it "ran" and started fine, it just needed some love. I started with some routine things - cleaned airbox, new plugs, deleted smog stuff, tuned the carbs a little - and mainly just rode it a bunch to get it used to being ridden again. I began making long lists of things I wanted to do to it and how I wanted it to look to tackle over the winter... which is what you will be following with... everything from modifications to routine maintenance to stripping, repainting, parts refurb and updates. Hope you enjoy!


So - an update and some photos to the build so far after a few months of winter slumber. I have been pretty productive in my spare time and read through the boards often.

Previous LIST:
    removed krausers & brackets
    relocated rear turn signals
    header wrap
    Cone Engineering mufflers
    Made new battery pad
    Rebuilt airbox
    new air filter
    new spark plugs
    new intake boots (airbox and carb side)
    new vacuum lines (airbox and carbs)

RECENT UPDATES:
- Bings stripped, cleaned, rebuilt & painted
- New throttle cables
- Handlebars stripped, painted, controls cleaned
- New grips and titanium ends installed
- Tank removed, re-lined, out for paint
- New petcock and filter
- New motion pro fuel line & new filter
- Brake calipers blasted, painted, new rebuild kits & new pads installed & ready for assembly
- Front forks removed, cleaned, legs blasted, painted & internals rebuilt - forks aligned and going back together this weekend
- Acewell gauge acquired (have enlisted electrical engineer friend to assist on wiring)
- Speigler stainless brake lines acquired and ready to install after forks go together
- Acquired 2 spare fenders to cut-down/modify and front fender is out for paint- rear will be mocked up once new subframe is sourced/installed
- Acquired set of X-Arc signals for from and X-Arc brakelight/signal running lights for the rear.
- Replaced spark plug wires (noticed some dry rot on old wires)
- New Clubman headlight acquired and is being mocked up and prepped for wiring

Still To Do:
- Finish front end rebuild
- source battery
- Make mount for ignition & acewell
- new subframe
- new rear shocks
- new seat
- finish re-assembly
- hope it starts
- oil/filter change
- adjust valves
- sync carbs

Road tests all summer  Grin

Photos coming of progress so far....


« Last Edit: 03/12/17 at 14:29:54 by marcmiller001 »  

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Marc Miller
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marcmiller001
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Re: New Member - '82 R65LS
Reply #1 - 03/10/17 at 10:52:44
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As promised - here are some photos of the tear-down process and where I am to date.

Pic 1 - Tear down process of front end and removing gauges

Pic 2 - Labeling

Pic 3 - Prepping to drain forks and assess rebuild

Pic 4 - Forks and clamps removed - tank removed

Pic 5 - Top clamps before

Pic 6 - Missing bushings = a mess inside

Pic 7 - Top clamps blasted, repainted
  

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Marc Miller
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marcmiller001
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Re: New Member - '82 R65LS
Reply #2 - 03/10/17 at 11:00:32
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Pic 8 - Stripped, cleaned and repainted handlebars - mocking up position

Pic 9 - Mocking up headlight and X-Arc turn signal locations - added new grips

Pic 10 - New titanium end caps and controls going back together

Pic 11 - Carbs rebuilt, painted and back on - also new plug wires

Pic 12 - waiting on new bushings (arrived just now!) and going back together this weekend.
  

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Marc Miller
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marcmax
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Re: PROJECT BIKE - '82 R65LS ACQUIRE & REBUILD
Reply #3 - 03/10/17 at 20:58:51
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I've never seen black Bings before. I think I like it! Gives a nice contrast to the expanse of aluminum that is a side view of these motors.
  

Keep your bike in good repair:  motorcycle boots are not comfortable for walking.  

1982 R65ls        1984 R65ls        1991 K75
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marcmiller001
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Re: PROJECT BIKE - '82 R65LS ACQUIRE & REBUILD
Reply #4 - 03/11/17 at 07:26:23
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marcmax wrote on 03/10/17 at 20:58:51:
I've never seen black Bings before. I think I like it! Gives a nice contrast to the expanse of aluminum that is a side view of these motors.


I had seen them on another bike before and thought the same thing. Since I had a lot of down-time when the bike was stripped and had to go through the carbs anyways, I figured I'd paint them. The process wasn't very difficult - lots of soapy water, scrubbing, soapy water, taping up. I used VHT Satin Black Epoxy paint - which is also what I used for the front forks and handlebars and they seem to be holding up well. We'll see what happens when fuel leaks all over them though  Roll Eyes
  

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marcmiller001
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Re: '82 R65LS Restoration
Reply #5 - 03/12/17 at 08:44:03
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Well - front forks are back together. Here are some details.

Pic 1 - All the new internals accounted for. I left out one of the shims (not pictured) as I only received one. Apparently that shim is to help with noise?? I had not seen anyone use one before, so left it aside.

Pic 2 - Fork assembly all together. Also put new felt insert in the dust caps.

Pic 3 - side view of the painted lowers.

Pic 4 - Adding some extra touches - some pannier badges to replace the reflectors.

Pic 5 - Completed lowers (minus brakes/axle)

Pic 6 - Last step was to add fork oil. I used 10 WT Maxima (it is clear). Since I also put new progressive springs in with a short spacer, it was recommended to use 140cc of oil instead of 190cc... I put in 150 since it was all new... suggestions on anyone who has done this before and feedback on oil levels would be great!

Next steps are to install new choke cables and clean and re-install the wheel and front axle, brake calipers and new brake lines (stainless steel Spiegler).
  

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Marc Miller
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marcmiller001
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Re: '82 R65LS Restoration
Reply #6 - 03/13/17 at 12:14:14
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Did a pic more work to the bike last night - before I have a 12 day trip ahead of me. I believe I just ordered a Vonzeti sub-frame and seat... and hoping it matches up well.... in the meantime, still plenty to do from the front.

Pic 1 - forgot to add that these are the springs that went in.

Pic 2 - Cleaned and mounted up front wheel, brake calipers, fender bracket and new spiegler stainless brake lines - ALSO mounted and adjusted the choke cables, which were replaced as well.

Pic 3 - The lines didn't put up much of a fuss at all, adjusted the angles based on the recommendations on the package and they look very nice. These were stainless, clear wrapped with titanium ends, which will be an accent color for the bike.

Pic 4 - Here is how she sits (though this was before the lines and calipers mounted)

This will likely be how it will stay for the next few weeks until electrical work begins upon return. Have a headlight, turn signals and an Acewell gauge to fit, wire and troubleshoot before the tank paint and subframe/seat arrive.
  

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Marc Miller
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Re: '82 R65LS Restoration
Reply #7 - 03/22/17 at 22:51:51
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I really like the emblems instead of the reflectors!
  

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marcmiller001
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Re: '82 R65LS Restoration
Reply #8 - 03/28/17 at 18:40:10
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Thanks Justin. It really sets it off.

Latest update... the orings I used when I split the ATE calibers aren't sealing. Just ordered another set from Pelican and hoping they seal. Spent over an hour trying to bleed the brakes only to have air in it no matter what. I figure it is coming from the split and air coming in through old o-rings. Pistons move slightly...all 4...none are sticking.. but never can build pressure in the master cylinder but no visible leaks. Hoping to split and have sorted next week.

In the mean time putting attention into wiring! Yay. A new headlight assembly? X-arc blinkers and an Acewell gauge need to get sorted. Thankfully having a friend swing by to help out.
  

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Re: '82 R65LS Restoration
Reply #9 - 03/28/17 at 18:52:46
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marcmiller001 wrote on 03/28/17 at 18:40:10:
the orings I used when I split the ATE calibers aren't sealing.


Marc, .........do you see them leaking when you try to pump up the system? How are you bleeding the system? Those brakes can be a real bear to bleed at times.
  

Joe Wilkerson
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Present:
1984 BMW R65LS "Herr Head"
past:
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1980  R65          
1982 R80RT 
1974 R90/6     
1972  R75        
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marcmiller001
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Re: '82 R65LS Restoration
Reply #10 - 03/29/17 at 17:31:34
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wilcom wrote on 03/28/17 at 18:52:46:
marcmiller001 wrote on 03/28/17 at 18:40:10:
the orings I used when I split the ATE calibers aren't sealing.


Marc, .........do you see them leaking when you try to pump up the system? How are you bleeding the system? Those brakes can be a real bear to bleed at times.


Well - I don't see them leaking - or feel it... but I went through a whole bottle of fluid and there was still no pressure in the master (or an increase at all). I am making a bit of an assumption that the only thing not replaced (the internal o-rings) is causing the issue.... so I ordered some from Pelican and going to at least bang my head against the wall knowing I replaced everything first.  Grin
  

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Re: '82 R65LS Restoration
Reply #11 - 03/30/17 at 13:42:18
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marcmiller001 wrote on 03/29/17 at 17:31:34:
Well - I don't see them leaking


My thinking is that if it lets air in it would let fluid out under pressure.

I've always struggled bleeding small braking systems, I swear I have one forearm larger just because of pulling on that lever a million time  Grin

There are folks here that are very keen when it comes to these issues, maybe one will chime in
  

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1984 BMW R65LS "Herr Head"
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Re: '82 R65LS Restoration
Reply #12 - 04/07/17 at 11:42:56
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Well, been quite a busy 2 weeks of continuing the R65LS project in between travel and family.....

Here are the updates....

I determined that the lack of ability to bleed brakes was due to that damn little square o-rings... once I received the ones from Pelican I put them back together, mounted them on the bike and started the bleeding process. 20-minutes later I had no bubbles and a firm brake handle... so I consider my front brakes to be 100% refurbished. New EBC pages, rebuild calipers and M/C, new spiegler stainless lines and some Maxima Dot 4 and we are back in business.

Next step was to set my sights on wiring up the new H4 headlight from Revival... and the X-arc flashers/brake lights. I had ordered black billet aluminum headlight mounts from MAX out of australia.... and they look great.  Once fitted - it all had to come back off again to wire it and thanks to a good friend who is also a talented racing engineer who is pretty good at wiring - we also began tackling the Acewell 4453 gauge.

I mounted up a temporary bracket to get it out of the way and allow us to sort through the mess - huge thanks to this and another forum for all the background on wiring up this thing. We are about 90% through it right now.

So far, we have: turn signals, oil light, speedo, rpm and the clock. All the settings are set. We plan on using a resistor and tie-ing the GEN light into the 4453's hazard function so we don't need an extra light mounted somewhere. For the S-11 digital speedometer lead, I had to remove the oval connector from the magnet speedo lead and mount that on the end of the S-11 lead so it will mount up to the 4453. Apparently this is something you will need to do for 4 & 6-series dashes to work with that S-11 lead. Since I have a lot of data acquisition parts laying around, I found an RPM wire end and routed the RPM lead through to attach to the new NGK plug wires. This should give us a clean and hidden RPM wire.

Next was to route the digital speedo lead and neatly secure it to the frame.....

At this point I am cleaning up and color coding the connectors - but it is almost ready to start organizing and hiding the wiring inside the headlight bucket.

The carbs are all plumbed but I am waiting on my subframe, seat and fuel tank still - but I am planning on using a "temporary fuel tank" to warm up the engine and make sure it starts, runs, etc before doing valve adjustment & oil change. I have already routing fuel lines and installed a fuel filter - so I imagine it can be started and warmed up. During oil change I plan on tapping the oil filter cover and installing the supplied temperature lead so I have oil temp.

This has been a fun project - but it becomes more and more enjoyable the closer I get it to being ride-able!
  

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Re: '82 R65LS Restoration
Reply #13 - 04/07/17 at 21:49:20
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Making excellent progress, Marc!
  

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marcmiller001
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Re: '82 R65LS Restoration
Reply #14 - 05/27/17 at 19:42:37
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Well - let's see where we left off!

Still had a lot to do - and posted this a few weeks ago during the host change and lost two long posts and about 14 photos...but have been traveling and enjoying the nice weather so unable to post until tonight - and I was inspired by a great ride today with lots of head turns and thumbs up!

Where I left off was - more wiring! I still had to work on getting all the wiring sorted for the Acewell 4453 and huge thanks to a local racing buddy, we got a long ways down the road.

Photo 36 - I managed to get the GEN light sorted and tested then went to work on testing the rest of the wires and making sure the headlight and X-arc lights worked.

Photo 38 - Mounted the headlight assembly and LED signals up, then plugged the ignition switch back in and zip-tied it all in place to do a test.....

Photo 39 - Turned the ignition on and BOOM - we have lights, high-beams, turn signals. All working properly.... but I still had to start it to make sure the gauge read properly and GEN light was functioning correctly.

Photo 41 - I know I know.....but I REALLY wanted to hear it run and make sure the wiring was correct and gauge worked properly to that point....and since I still needed to drill and tap the oil filter cover to insert an oil temp probe, I needed to get it warm to drain the oil....

Photo 43 - Didn't take long and it fired and was able to warm it up. It didn't idle great but the valves had not been adjusted and the carbs were reset to factory stock settings and a complete overhaul - but it felt GREAT to hear it run and shot some videos to send to my friends that had helped me along the way.

Photo 45 - After draining the oil, the oil filter cover was pulled, old filter checked and discarded and the cover drilled and tapped.

Photo 46 - Here is the finished product - now have oil temp sensor in a good location.... of course the oil filter and seal was replaced and new oil put in. I had a hard time located a good oil so filled it with Valvoline 4T oil temporarily as I knew I would change it out one more time before I really started riding it.

Photo 47 - I took this time to pull the valve covers, clean them and inspect - and adjust the valves. they were VERY tight.... and reset them twice to make sure - thanks for all the help on the forum to getting it sorted.  During this process, I found the center cover studs to be stripped. I cleaned one up and replaced another. Was an easier job than I expected. Double checked the valves and put new gaskets and valve covers back on.... fired it up and began the carb tuning process to at least get to idle and run "ok" - I dealt with quite a bit of misfire and cold cylinder on the right side before it seemed to sort itself....

A lot accomplished....but still so much more to go!

  

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Re: '82 R65LS Restoration
Reply #15 - 05/27/17 at 19:54:56
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OK.... lots to catch up on still!

The project continues.... now that I have it "running" - I have to finish up fab'ing up brackets, mounts, etc before I can get it on the road... and oh yea, I don't have a fuel tank either - so hard to really get a ride in like that... so during this down time, it was a great opportunity to go through and sort the wiring, fab up some brackets and go over the bike with a fine toothed comb.

This entire run of photos is simply the fab work done for the Acewell/Ignition/Gen light mount. I wanted something quite simple, strong and industrial - so a trip to the hardware store I came home with a steel plate.

Photo 51 - as the bike sat after valves, oil change, etc..

Photo 52 - I took some measurements and made up a few samples out of cardboard for mock-ups....

Photo 53 - I wanted to make it rather small, not interfere with the clutch/throttle cables... and that took a few tries and decided on this layout.

Photo 54 - Next it was time to sketch/trace them onto steel.

Photos 55, 56, 57, 58 - I took them to a friend with a proper fab shop who also welded up my stainless exhaust brackets for me. He and I cut, drilled, bent and rounded the edges....

Photo 59 - One I got the bracket back to my garage I sanded and mounted it. I used some spacers (cut aluminum rod for a nicer spacer than washers) to give it distance for the cables.... Everything looked nice so it was ready to start cleaning up wiring and mounting up the gauges, ignition and GEN light.

Next was to get the "organizing of wiring" and headlight mounted back together!
  

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Re: '82 R65LS Restoration
Reply #16 - 05/27/17 at 20:20:42
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..... and the saga continues!!

Next up in this list is to sort and organize all the wiring for the headlight/bucket and route it neatly and in a tidy fashion which proved to be a lot more difficult..... as well as figure out a nice way to mount my license plate!

That Acewell 4453 is a great gauge - however - it has a TON of wiring that I didn't need and the clubman headlight I got didn't have a ton of extra room to hide a lot of it, so tucking it away was a bit of a challenge...

Photo 60 - I ordered a roll of TESA tape and some braided cable sleeve. I started with the ignition switch, then the headlight and turn signal wires, then wrapped all the other extra wiring. Like I said, it was a challenge!

Photo 61 - With the gauge and ignition switch mounted, it looks quite nice from the top, even though it was a tight squeeze underneath.... the GEN light was difficult as I had to made the hole large enough to get it through without soldering it after it was mounted - so I used a nice aluminum angled washer for it to set down in. I polished the washer up as well.

Photo 62 - This photo shows a look from underneath prior to healight being mounted. I have since changed out the bolt and nut for the gauge to a nicer looking and better length....

Photo 63 - once headlight was mounted, it was time to finish tucking cables away. I actually had to mount and dismount the headlight a few times to figure out the cleanest way as to not chafe the wiring or the painted surfaces. So far I have not seen any issues.

Photo 64 - Finally - the front wiring is done and everything is mounted as it should be - and most importantly - functioning properly!

Photo 65 - Next my attention turned to the back of the bike. I had my license plate hanging up on the wall for 6 months with numerous thoughts on where it should be. I still had not even heard back from VonZeti about either my seat or subframe in almost a month and a half - so I figured I didn't want to mount it off the subframe anyways - and since I couldn't mount my rear fender I was modifying until the subframe arrived - I guess I didn't have a lot of choice. I had seen some people mount them off the final drive and I didn't feel too keen about that either, so I used the pinch bolt for the rear axle and some steel strap that I drilled, bent and rounded the corners off of. The result was pretty good - even though it isn't legal in many states - I figure when I am done with this bike, an officer has to be having a pretty piss-poor day to write a ticket for it.

Photo 66 - The view from the posterior.... clean and tide location, easily visible.... once the subframe arrives, I also plan on adding a white LED to shine straight down to illuminate it.

Photo 67 - This last photo is simply because Forgeline, who is a marketing partner of the race team I drive for, sent me this nice little light-up pen & stylus... and I would LOVE to see them take a stab at some custom wheels for me.  Grin

....so that is the latest on my project R65LS build.... have a long list of TO DO's still... and a lot of "waiting around on other vendors".... but the remaining task list includes...

> Rear subframe
> custom seat
> Custom painted tank & fender
> New Continental ClassicAttack tires
> modified rear fender (using a front R65 fender purchased from ebay)
> Rear brake clean & adjust
> Rear spline lube
> Several maintenance bits
> Neutral switch replacement (current leaks badly)
> Another oil change & oil pan gasket replacement (to stop the leak)

STAY TUNED!

  

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Marc Miller
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'82 BMW R65LS
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Re: '82 R65LS Restoration
Reply #17 - 05/27/17 at 20:29:34
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Great job Marc...... Love the temp gas tank, never make it thru tech with that Grin
  

Joe Wilkerson
Telephone man with a splash of Data
Menifee, CA

Present:
1984 BMW R65LS "Herr Head"
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1980  R65          
1982 R80RT 
1974 R90/6     
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1964 R50
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Re: '82 R65LS Restoration
Reply #18 - 05/27/17 at 21:04:10
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Excellent progress!  I saw some pics of the "real" tank on your instagram page, looks cool!

Speaking of generator light, make sure whatever you use is in the same circuit location as the stocker as it is actually part of the charging circuit!  Same as the damnable Lucas stuff in the MGs I've had...

Glad you enjoyed Texas, I mentioned to my wife you were racing in Austin and she said we oughta go but just couldn't make things work, schedule wise, on such short notice.  Maybe next time.

As I mentioned in a post that I accidentally wiped out (sorry, really) your oil temp pickup point is an excellent idea and I bet it gets about as true a temp reading as possible.
  

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Re: '82 R65LS Restoration - oil temp pickup
Reply #19 - 05/28/17 at 07:17:55
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Marc
I saw another member congratulate you on the positioning of your oil temp sender and decided to have a look.

Neat placement, but please be very sure that both the threads and the device itself can handle high pressure - these boxers can develop extraordinarily high oil pressures, especially wen cold.

  

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Re: '82 R65LS Restoration - oil temp pickup
Reply #20 - 05/28/17 at 09:40:19
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Hey Tony - the fitting uses a pipe-thread, so it is tapered...which typically is great for high-pressure. So far - zero leaks and seems to work flawlessly, but I will keep an eye on it!

Tony Smith wrote on 05/28/17 at 07:17:55:
Marc
I saw another member congratulate you on the positioning of your oil temp sender and decided to have a look.

Neat placement, but please be very sure that both the threads and the device itself can handle high pressure - these boxers can develop extraordinarily high oil pressures, especially wen cold.


  

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Re: '82 R65LS Restoration
Reply #21 - 05/28/17 at 09:41:11
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wilcom wrote on 05/27/17 at 20:29:34:
Great job Marc...... Love the temp gas tank, never make it thru tech with that Grin


haha - thankfully - no tech here... wait until you see what I did to ROAD TEST it without a tank  Shocked Cool Wink - pics coming!!
  

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Re: '82 R65LS Restoration
Reply #22 - 05/28/17 at 09:42:50
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Thanks Justin - I tested the circuit, followed the right procedure and it charges - though my updates are slow - I have over 100 miles on it so far and have not had to charge or had a loss in voltage at all. All seems great!

Justin B. wrote on 05/27/17 at 21:04:10:
Excellent progress!  I saw some pics of the "real" tank on your instagram page, looks cool!

Speaking of generator light, make sure whatever you use is in the same circuit location as the stocker as it is actually part of the charging circuit!  Same as the damnable Lucas stuff in the MGs I've had...

Glad you enjoyed Texas, I mentioned to my wife you were racing in Austin and she said we oughta go but just couldn't make things work, schedule wise, on such short notice.  Maybe next time.

As I mentioned in a post that I accidentally wiped out (sorry, really) your oil temp pickup point is an excellent idea and I bet it gets about as true a temp reading as possible.

  

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Re: '82 R65LS Restoration
Reply #23 - 05/28/17 at 09:47:23
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Ditto on what Tony said about pressure.  I installed a 150 PSI gauge on the "Project Junkyard Dawg" and first startup on cool morning I had to remember to keep the revs down for a few minutes or I would peg the meter!
  

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Re: '82 R65LS Restoration
Reply #24 - 05/28/17 at 11:18:40
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.... Justin eluded to seeing some photos of my tank on instagram - but here is the process. My goal was to have a clean look - so chose matte satin, matte white and a matte titanium color, which matched some of the accents on the bike such as the handlebar end caps and brake lines.

My helmet painter of 12 years, Mike Corby (Corby Concepts in Indianapolis) was tasked to do the work for me. He also had to completely repair the local place did when they "fixed it" and re-coated the inside for me... I was charged for pretty crappy work - then charged again to fix it after the fact. This was pretty much the only regrettable part of the build to date.

Photo 68 - Tank and modified fender with first round of satin.

Photo 69 - Taped off and ready for next color - titanium

Photo 70 - This was a special color Corby made up - called Platonium. It works well.

Photo 71 - Masked and the "platonium" stripe going on

Photo 72 - 2nd round then dry....

Photo 73 - Removed - now ready for a matte white to finish it off. Once that is dry, then several rounds of satin clear go on!
  

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Marc Miller
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Re: '82 R65LS Restoration
Reply #25 - 05/29/17 at 09:43:05
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Got some shipments in a few weeks ago.... some meant "more maintenance to do" and others were ..."HELL YEA.... FINALLY IT WILL LOOK LIKE SOMETHING!"

I received:
- Oil pan gasket and miscellaneous washers
- NEW Continental ContiClassicAttack tires
- My painted fuel tank!!!
- New BMW roundels for tank

At this point, I was planning on some more maintenance.... the TO DO list included...

- Warming up the bike
- Taking it for a little spin around the block to warm up gearbox, shaft and final drive oil
- Drain ALL fluids
- Replace oil pan gasket and clean pick-up
- Refill with all fresh fluids and check for leaks

Photo 74 - The first issue was opening up the package and finding a cracked gasket! I called up BMW Motorcycles of Countryside and they sent out a replacement, next day - no charge. These guys have been ROCK SOLID for me in getting this bike mechanically sound. I have ordered ALL of my BMW replacement parts from them and their techs and parts guys have been hugely helpful.

Photo 75 & 76 - Next was figuring out a way to warm up all the fluids without a seat or fuel tank.... I opted to create a smaller "portable" tank out of a water bottle... and I remounted the original subframe and placed a floor pad on that. Yes, I know... looks janky as hell - but I wanted to make sure everything functioned and wanted to do all the fluids before re-assembling and fitting with a tank. It fired right up and I set off within my subdivision to do a few laps to warm up the fluids. All was going great until it started to sputter and die. I looked down...gave the bottle a few squeezes and she came back to life. I went through the whole bottle nearly..... and that was good for just over 3 miles of circulating around safely through the neighborhood.

I parked the bike, drained the oil, dropped the pan, drained the gearbox, final drive and shaft oil - then set about replacing the neutral switch, cleaning the pain and the bottom of engine, checking and cleaning the sump screen and took my time reassembling everything.

I took this time to replace the Valvoline 4T oil with 20W-50 Valvoline VR1 and filled the gearbox, shaft and final drive with Valvoline gear oil. I fired it up again and let it idle.... checked fluids again.... and was happy to see NO LEAKS!! Success - a boxer that doesn't leak for now, it either out of oil or is well-sealed  Grin

Photo 77 - I was especially happy to receive these ContiClassicAttacks as well. These look great and was ready to start pulling off the wheels and take them in to get swapped out!

Photo 78 & 79 - The tires though went into the corner when the other box arrived from my racing helmet painter.... I was anticipating this baby!!

Photo 82 - Also 2 new BMW roundels showed up.... perfect timing as well! Kid in a candy store!

Photo 84 - I noted a very cracked and worn out o-ring for the filler cap as well, so texted my parts guy and ordered a replacement - they were in stock and received it the very next day.

So we are getting close to caught up and was able to spend some fun evenings emptying boxers and figuring out what to do next!

STAY TUNED!
  

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Marc Miller
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'82 BMW R65LS
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Re: '82 R65LS Restoration
Reply #26 - 05/29/17 at 18:13:40
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Marc, if you don't quit it'll be too purty to ride!
  

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Re: '82 R65LS Restoration
Reply #27 - 05/30/17 at 09:04:09
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Justin B. wrote on 05/29/17 at 18:13:40:
Marc, if you don't quit it'll be too purty to ride!


No way!!!  Grin
  

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Re: '82 R65LS Restoration
Reply #28 - 05/30/17 at 23:06:44
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Your tank sealed the deal for me on my R100RT fairing re-paint.  I have almost all of the chips and cracks fixed and was trying to decide between gloss black (like rest of bike) or sem-gloss black.  I think I'm going to use the rest of that quart of Dupont "Hot Rod Black" and kinda stealth it.  Cool  I may be able to get back to it now that the '57 has AC!
  

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Re: '82 R65LS Restoration
Reply #29 - 06/02/17 at 11:02:22
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Hey again folks - I am just over a week away from debuting my project bike build! This is the only forum I have really kept a running tab of the progress, but will be writing up a full build report with some nice photos in the next couple weeks.

Some cool things!

1. Tank got MOUNTED and all seemed well... and I put the old subframe and seat to run a tank or two of fuel through and work out some tuning issues - which now seem solved!

2. The seat and subframe arrived!! (FINALLY)

So let's catch up!

Photo 80 - Corby Concepts nailed my request and I mounted up this gorgeous satin and matte white/titanium finish tank. A far cry from where it started with.

Photo 81 - The tank fitment on the R65's seem easy - but I wanted to protect the tank and frame a bit more so used some high density foam cut and fitted to the center section (about 4" long) and then on each side where the back of tank gets close to the inside edges of the tank. Secured with industrial strength 2-sided - they make the fitment secure and avoids any jarring or extra movement in the tank.

Photo 83 - With the new roundels.... it really has a nice look to it.

Photo 89 - I installed a new petcock, ran the fuel line, installed a new filter (which I replaced once already due to the clogging (new painted tank blues) and re-installed the old subframe and seat to do some test rides. I opted to ride out to Lake Michigan and Holland state Park and take a shot of it as it sat - in the same pose as I took a photo of the original LS I received in Fall of last year. It looks nice, but still looks unfinished...

Photo 95 - After returning from two weeks of work trips and still no word on my seat/subframe.... I decided to pull the wheels/tires and do maintenance on the rear spline, inspect/clean rear brakes and have my new ContiClassicAttack tires mounted up. One thing I did notice on one of the test rides - with my girlfriend on back - was the old shocks had to go - soon... so I looked further into ordering the set of YSS shocks I had researched months ago.... I pulled the trigger a week later.

Photo 96 - A few days later - a shipment from UK-based Von Zeti arrived!!

Photo 101 - But first....maintenance work. I used some Castrol moly from BMW Motorcycles of Countryside.

Photo 97 - ....and here is the start of the fitting of the subframe. The quality is very sturdy and I was pleased with the design. It came primered and only needed slight tab adjustments to fit. I replaced all the hardware and used some shims to make it fit without tension.

....so that is the latest! Hope you guys are enjoying the build!
  

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Re: '82 R65LS Restoration
Reply #30 - 06/03/17 at 12:25:57
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That's a really sharp looking bike. I know that all of the pieces were going to be top notch but it came together as a whole really well.  I especially like how you managed to do some "chopping" and upgrading (modernizing?) but the end product is still recognizable as what the bike was originally.  Great job on customizing but keeping true to the roots.
  

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Re: '82 R65LS Restoration
Reply #31 - 06/04/17 at 17:59:16
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I'm anxious to see your finished product!
  

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Re: '82 R65LS Restoration
Reply #32 - 06/10/17 at 07:44:54
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Thanks for the compliments guys - this has truly been a journey. I am writing a proper blog for this and a story to go along with it - as well as have a couple photoshoots scheduled. Tomorrow, the bike's first public appearance will be at the Gilmore Vintage Bike Festival near Kalamazoo, MI.... so I am excited to hear feedback from people in person, but this forum is the first I have posted on with progress photos.... and have loved the feedback and assistance!

BPT wrote on 06/03/17 at 12:25:57:
That's a really sharp looking bike. I know that all of the pieces were going to be top notch but it came together as a whole really well.  I especially like how you managed to do some "chopping" and upgrading (modernizing?) but the end product is still recognizable as what the bike was originally.  Great job on customizing but keeping true to the roots.

  

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Re: '82 R65LS Restoration
Reply #33 - 06/10/17 at 08:20:45
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marcmiller001 wrote on 06/10/17 at 07:44:54:
first public appearance will be at the Gilmore Vintage Bike Festival near Kalamazoo, MI..


Bring back pics for us..... Grin
  

Joe Wilkerson
Telephone man with a splash of Data
Menifee, CA

Present:
1984 BMW R65LS "Herr Head"
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1980  R65          
1982 R80RT 
1974 R90/6     
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1964 R50
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Re: '82 R65LS Restoration
Reply #34 - 06/10/17 at 08:22:37
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Here is the latest round of photos I have processed and cropped.... hope you all enjoy!

I had mounted up the VonZeti sub-frame and had to make several tweaks just to insure there was no bind, but overall I was really happy with the fit. I got all new mounting hardware as well.

photo 99 - The seat I ordered with black leather with titanium gray stitching - as well as piping. It mounts with fender washers and nuts, but I replaced those with rubber washers, fender washers, a wave washer and (4) wing-nuts so that I had easier access to underneath the seat w/o the need to get tools out.

photo 102 - Here is an "assembled" image. I rode it like this a bit to make sure the fender height was ok during the ride - so I can hard-mount it. At this point, I knew I needed to removed rear fender and cut it down to match front fender. The rear fender is a R65 fiberglass front fender obtained from ebay for $15.... I made the front mount from aluminum angle mounted to lower cross-frame, a steel strap and some hardware.

photo 104 - front view. As you can see from last 2 photos I had the Continental ContiClassicAttack tires mounted up - and road test was great! Rear shocks don't really have any dampening control, so I had decided to replace those...

photo 105 - ...with a set of YSS shocks with adjustable pre-load and rebound adjustment. They "bolted right on" ... with some exceptions.

photo 106 & 107 - Being a racer, suspension geometry is pretty important to me and I tried to match up shock angles. I noted some weird angles the left rear shock cambered in and the right rear more positive. I used machined down chrome spacers in the top and bottom of the right shock and the top of the left to adjust them to get them within .1 to one another.

photo 108 - this is the top of the left side shock. The right side uses only one smaller shim.

photo 110 - bottom of right side shock spaced out for desired angle.

Next step was removing everything - again.... and finish up the rear fender modification & mount, paint the fender, sub-frame and various bits as well as re-assemble and re-wire the signals......
  

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Re: '82 R65LS Restoration
Reply #35 - 06/10/17 at 10:33:57
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Love your build Marc. It looks like it will be a blast to ride. When I had mine fully cafe'd I cut my front fender down similar to yours. I wasn't happy with the height it ended up at and trimmed about a half inch from the end of the fender brace and end of the fender mount tabs. Followed the curve of the tire better IMHO. I even mounted some pretty aggressive dual sport tires just for the look and had to clearance issues.
  

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Keep your bike in good repair:  motorcycle boots are not comfortable for walking.  

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Re: '82 R65LS Restoration
Reply #36 - 06/10/17 at 16:27:51
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Looks very slick, Marc.  Do you think the shock mounting geometry might have been due to the aftermarket subframe?  Now all you need are some rear-sets and you can lay down on it and cruise all day!

You need to get rid of the coathanger-wire shift link under that rubber boot I noticed in an earlier photo.  Pm me some shipping info and I might have one adjustable heavy-duty link left.

Good luck at the show!
  

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Re: '82 R65LS Restoration
Reply #37 - 06/11/17 at 06:02:06
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That would be awesome Justin! PM in process!

Justin B. wrote on 06/10/17 at 16:27:51:
Looks very slick, Marc.  Do you think the shock mounting geometry might have been due to the aftermarket subframe?  Now all you need are some rear-sets and you can lay down on it and cruise all day!

You need to get rid of the coathanger-wire shift link under that rubber boot I noticed in an earlier photo.  Pm me some shipping info and I might have one adjustable heavy-duty link left.

Good luck at the show!

  

Marc Miller
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'82 BMW R65LS
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Re: '82 R65LS Restoration
Reply #38 - 06/11/17 at 06:04:41
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It is quite possible. I still have original sub - so I might remove and check, but that makes sense. It is a beefy subframe from Vonzeti - much stiffer than original factory one.

Justin B. wrote on 06/10/17 at 16:27:51:
Looks very slick, Marc.  Do you think the shock mounting geometry might have been due to the aftermarket subframe? 

Good luck at the show!

  

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Re: '82 R65LS Restoration
Reply #39 - 06/11/17 at 06:17:25
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On the day of the debut... I wanted to give you guys a sneak peek!

Here is the latest updates....

Photo 112 - I removed the LED's and sub-frame to prep for paint. VonZeti sends the sub pre-primered, so I cleaned it up and shot it in satin black epoxy VHT, which is the same paint used for the carbs and forks. It has proven to be pretty stout.

Photo 113 - New YSS shocks resting - waiting to have something to grab on to.

Photo 115 - The sub took 3 coats of the Epoxy paint.

Photo 116 - At this time, I also finished the cut-down of the rear fender, and painted that as well as the rear license plate bracket/mount.

Photo 118 - All my new hardware was laid out and ready for final assembly. Wingnuts, rubber & fender washers for the seat, Long countersunk bolts with aluminum spacers, fender washers and fiber washers for top of rear fender, and hardware for the front of the rear fender bracket. Also in that mix were my X-arc rear lights that you have to snake through the sub-frame hole, and then snake all the wiring through a washer and a nut. It was a tedious process in both wiring and removing and replacing the signals several times.

Photo 121 - Subframe finally got mounted - and fitted for no bind, shocks re-attached.

Photo 122 - Next up was re-routing the X-Arc signals back in and preparing for the wiring.

Photo 123 - Then it was the license plate bracket mounted on the pinch bolt for the rear axle, then torque to spec.


  

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Re: '82 R65LS Restoration
Reply #40 - 06/11/17 at 06:28:51
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...and the final assembly is completed!!!! and ready to ride down to Kalamazoo, MI for the Gilmore Vintage Bike Festival!

Couldn't be happier to share the completed project with you guys.

Photo 124, 125 & 126 - Next step was to re-fit the custom cut-down rear fender. I used dual mount points from the sub-frame - with the sub-frame drilled and countersunk.

Photo 127 - Next up was getting the rear lights re-wired back and secured. I used a nice wrap. Not shown  in this photo is the 1/4" wrap I used for the side wires to match - then sealed it all up with Tesa tape for weather-proofing.

Photo 128 - Only needed one zip-tie to secure in place and it is ready for the seat!

Photo 129 - Here is the completed bike, shot in my garage. The next day, I rode it down 20 minutes to a photo studio for some "proper" photos to use in my blog build story. I will post those when available as well as any links where the bike gets shared.

ORIGINAL BIKE PHOTO OF R65LS - And this is what it looked like in October of 2016, in "ok" condition minus the Krausers.

Feels good to have it done, but I have a feeling - it will never be truly done. Since this thing is mostly hand crafted, I'm already looking for things I can update... the frame and engine could be disassembled and painted, some of the brackets could be replaced, I would love to get some custom leather bags to fit where the side skirts used to be... I have plans of making a seat pan for storage and an easier/quicker way to access under the seat. Electric upgrades or custom foot pegs might be cool too... that is what I love so much about this project is it really never has to end.... but I am very happy to be where it is now and can't wait to ride it down to the Festival today and share it with thousands of people.

Thanks all!
  

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Re: '82 R65LS Restoration
Reply #41 - 06/13/17 at 19:26:29
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Well, Marc, tell us about the Festival!
  

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Re: '82 R65LS Restoration
Reply #42 - 06/15/17 at 07:38:06
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It was great! Seemed like hundreds of bikes were exhibited, several hundred showed up... an entire field of parking filled with bikes. Beer tents, plus the Gilmore Museum is an amazing experience regardless with cars of all eras on display.

I got down there a bit late with my buddy (who had a Kawi 400 Mach 2 and another friend on his Harley. No issues on the ride down - other than a slight tire rub on the rear fender.... which was fixed by raising the mount point on the rear fender to the subframe after I returned home. Also, I pulled the tank and sloshed it around, emptied it, cleaned my fuel filter and my petcock filter and there is no signs of slow fuel flow anymore.

The bike is a joy to ride - nimble, quick acceleration - not to mention a major head-turner. Riding into the show it got a lot of looks, compliments and photos taken - which makes me extremely happy.

This was my first bike festival and was really happy to see a large array of bikes there... I am not a harley fan, and that seems to be the only bikes around - so the fact that there were Nortons, BSA's, BMW's, Guzzis, triumphs, ducatis, hard to find japanese bikes & several custom bikes. I will post up some pics when I get them off my phone.

Justin B. wrote on 06/13/17 at 19:26:29:
Well, Marc, tell us about the Festival!

  

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Re: '82 R65LS Restoration
Reply #43 - 06/15/17 at 07:40:31
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Also - here is one of the glamour shots of the bike.....  Smiley
  

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Re: '82 R65LS Restoration
Reply #44 - 06/15/17 at 15:17:52
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Marc,

Lookin' good, I'm sure that sponser will be pleased!  Wink

But, the more I look at your pictures the more it seems like maybe you have the valve covers swapped.  Although they will fit on either side the fins wont sit level if they've been transposed.  It might be a trick of camera angles but yours seem to be pointing "up" instead of level.  Unless that's the affect you were after, like it's trying to get airborne!
  

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Re: '82 R65LS Restoration
Reply #45 - 06/15/17 at 19:30:25
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funny you say that - but that isn't the case.... only 1 is swapped, because the bike came with TWO LEFT SIDE VALVE COVERS  Grin

I bought another off ebay - thinking a spare might be handy and it too is a left. I'd be happy to swap with anyone out there looking for a lleft side in really good condition for a right side :-D


Justin B. wrote on 06/15/17 at 15:17:52:
Marc,

Lookin' good, I'm sure that sponser will be pleased!  Wink

But, the more I look at your pictures the more it seems like maybe you have the valve covers swapped.  Although they will fit on either side the fins wont sit level if they've been transposed.  It might be a trick of camera angles but yours seem to be pointing "up" instead of level.  Unless that's the affect you were after, like it's trying to get airborne!

  

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Re: '82 R65LS Restoration
Reply #46 - 06/15/17 at 20:01:28
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OK, I reckon that would 'splain it!
  

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Re: '82 R65LS Restoration
Reply #47 - 07/15/17 at 06:04:32
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Hello Marc,
You've done an excellent restoration job. I started a similar project myself and I also used the acewell tacho with a cable drive speed sensor. Can you please tell me what setting are you using for the wheel circumference? I have tried 1436 but it's not accurate enough.
Thank you,
Radu
  
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Re: '82 R65LS Restoration
Reply #48 - 07/15/17 at 06:06:53
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Here is a photo of my old girl
  
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Re: '82 R65LS Restoration
Reply #49 - 10/11/17 at 13:33:00
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Hi there... let me go out in the garage when I can and I will tell you what it is set to.... but what I did was use a GPS app on my phone, ride down the road for a kilometer or so... at a set speed.... then checked my GPS max speed. 3 runs and I had found my setting that was within a half mph of my actual speed.

sauasa wrote on 07/15/17 at 06:04:32:
Hello Marc,
You've done an excellent restoration job. I started a similar project myself and I also used the acewell tacho with a cable drive speed sensor. Can you please tell me what setting are you using for the wheel circumference? I have tried 1436 but it's not accurate enough.
Thank you,
Radu

  

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