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Very Hot Topic (More than 25 Replies) I used to be a Rat Bike... (Read 452 times)
Tony Smith
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Re: I used to be a Rat Bike...
Reply #30 - 03/02/19 at 04:44:55
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Re airbox

Chuck the 3mm plate at the end of the starter cover, you don't use it. The airbox is located by one central bolt and 2 bolts that clamp the airbox to the starter cavity.

Near the central bolton the top of the gearbox you will see a tempting little phillips headed screw - Do not under any circumstances remove that screw. It retains a piece of steel channel inside the gearbox that lubricates the gears and bearings by flooding them with oil collected in the channel  by being thrown there by the input gear. Undo the screw and the channel falls onto the gears, if it doesn't get "eaten" will will make a lot of noise and the gear/bearings will die of lubrication failure.

You might want to go to Real OEM and get a feel for the airbox components and where they go.
  

1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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Justin B.
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Re: I used to be a Rat Bike...
Reply #31 - 03/02/19 at 14:49:55
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ged in oz wrote on 03/02/19 at 03:01:00:
Iím assuming that the filter sits between the two sections to fill out that gap?, or do I have the wrong airbox?


Yes, the air filter makes up the difference.  Also, make sure you have the "snorkles" on the airbox cover as I've read that performance suffers if they are removed.
  

Justin B.

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1981 R100RT - Summer bike, NEKKID!!!
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ged in oz
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Re: I used to be a Rat Bike...
Reply #32 - 03/02/19 at 15:09:03
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Tony Smith wrote on 03/02/19 at 04:44:55:
Re airbox

You might want to go to Real OEM and get a feel for the airbox components and where they go.


Wow. I might have been stuffing around for years before I found that Tony! Awesome. Thank you. The young fella I bought the bike off hit on me for an extra 50 bux for the Clymer manual which is great, but it isnít really model specific and it doesnít show exploded assembly diagrams like that. Exactly what I needed.

Thanks for tip on the screw as well. Yup, that could go very wrong...

  
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ged in oz
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Re: I used to be a Rat Bike...
Reply #33 - 03/02/19 at 15:14:43
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Justin B. wrote on 03/02/19 at 14:49:55:
ged in oz wrote on 03/02/19 at 03:01:00:
Iím assuming that the filter sits between the two sections to fill out that gap?, or do I have the wrong airbox?


Yes, the air filter makes up the difference.† Also, make sure you have the "snorkles" on the airbox cover as I've read that performance suffers if they are removed.



Thanks Justin. I was hoping that was what was happening. Iím waiting on another parcel form Moto Bins which has all my service parts including the air filter. The first shipment arrived in under a week, so itís only a couple of days away.

  
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BPT
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Re: I used to be a Rat Bike...
Reply #34 - 03/02/19 at 18:48:08
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If you hear of anyone mention "Max" or "parts fiche", here is what they're talking about.  It's a BMW dealer in the US that puts the fiche online.  Same pictures and such as Real OEM but set up a little bit differently.

https://shop.maxbmw.com/fiche/DiagramsMain.aspx?vid=51897&rnd=07242017

  

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Re: I used to be a Rat Bike...
Reply #35 - 03/02/19 at 19:49:12
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BPT wrote on 03/02/19 at 18:48:08:


Excellent! Thanks BPT. I really appreciate the help you guys are providing.

So, Iíve just dropped the Mrs at the airport which gives me a few days to make some real mess and spray motor bike parts all over the place for a bit, without ďah hmmĒs and ďoh, reallyĒs.  Smiley

It looks like a good opportunity to do the fork seals and have a look at the steering head bearings.

Iíve actually got a huge shed and workshop area, but itís already full of old motorcycles and projects and other crap! (my business actually takes up most of it). Iím hoping to have this thing mobile again within a few more weeks, so Iím doing all of this in the car port attached to the house, so itís kind of shared domain.


  
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Re: I used to be a Rat Bike...
Reply #36 - 03/12/19 at 16:56:26
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Well, that was quite a week. The boss is back and I managed to have everything mostly back together and on its wheels again before she arrived!

Front end all went pretty easily. I did wait a week for replacement bump stop rubbers ,(a soft, clear material rather than the red ones). Steering head bearings werenít too bad. They just got a good clean up, reassembled, fresh grease and adjusted.

The master cylinder was a mess. Full of some sort of molten muck, but again a good clean up and the internals were all fit to go back together. It certainly looked like a kit had been through it in the last couple of years. The reservoir had 3 good cracks in it, so that was replaced, fluids flushed and drained and it feels pretty good.

I replaced a lot of fasteners on my way through with 8.8 rated, zinc plated hex head bolts, (because that was all I could source locally), but Allen head replacements are at my post box waiting for collection.

Airbox system is complete again but I need to get the fuel tank sorted before I can get it running and test it all. No doubt the carbs will need adjustment and sorting, but weíll get to that in due course. Iíve still got to do oil change and valve clearances too.

The fuel tank! What a bloody nightmare... Iím still waiting on the US tank and old mate has messaged me to say that he spent an extra week trying to get the fumes out before posting it, which he was due to do on Monday.... hereís hoping it makes it.

So, while Iím waiting with my fingers crossed, I figured I ought to have a crack at straightening the original tank. I used the bladder method to push a couple of its dents out, but the main dent wasnít going to budge like that, so I resorted to welding a 20mmx20mm square tube offcut about 12mm wide to the tank and using a slide hammer to pull it out as far as I could. It was successful to a large extent, but it certainly wasnít pretty! I got most of the surface to within <10mm of its correct level and then treated the surface and stuffed it full of filler. Itís still got plenty of sanding left to get it right, but itís at least well on the way.

Iím waiting on shock absorbers to turn up and the fuel tank, (with its cap, which is what Iím really after) so give it another week or so, Iím pretty confident it will be fit for inspection and hopefully, plates.

  
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Tony Smith
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Re: I used to be a Rat Bike...
Reply #37 - 03/12/19 at 18:06:05
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That is looking seriously good. Well done!

I am really looking forward to seeing where this journey ends.
  

1978 R100RS| 1984 R65 | 1992 KLE500 | 2002 R1150GSA
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Re: I used to be a Rat Bike...
Reply #38 - 03/12/19 at 19:13:51
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Cheers Tony. Yep, itís coming on but Iím a bit of a ďglass half emptyĒ kind of guy, and all I ever see is how much work there is still to do. But thatís just elbow grease and man hours basically.

Where it ends up is still a bit up in the air. Iím keen to get it on the road and clicking off kilometres again and see where it goes from there. Iím more a fan of rolling restorations rather than complete strip down and rebuild, which tends to drag out and get wildly expensive.

Iím going to leave the single seat, bobbed rear guard and silly little LED taillights and indicators on it for the time being and pick up the bits required to return it to original as and when they pop up. Itís still a pretty extensive shopping list, (pipes, headers, rear guard, seat and tail unit, tool boxes, indicators, instrument surround) but they are generally all the bits that everybody is currently ripping off and discarding when building them into customs, so they are turning up fairly regularly.

Patience and persistence will be the key I suspect, which is fine if itís back on the road rather than taking up workshop space!
  
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