As of January 3rd, 2008, I figured I'd patch up this thread a little bit, so here we go: This is a mechanical pursuit, cosmetics will come years (haha) later. I’ve been with the same lawncare business for 10 years, and owned it from April 2004 to August 2008. One of my lawncare customers is/was a great guy, real talkative, real smart. In 2004, I noticed these two strange motorcycle shapes in his garage, hidden behind some boxes. Turns out, BMW makes motorcycles.. and we worked out a deal on his wifes bike. It had been sitting since about 1981, with gas in the tank, covered in cat urine, and all kinds of little demons here and there. I don't have any before pics, because I'm an idiot, but here is how she looks after a bit of money and work: Here's where I rescued it from: ..and ever since the day I got the R75, I had been dreaming of the R90 still sitting in there (YES, there IS a motorcycle in this picture): I kept mentioning to him that I REALLY wouldn't mind taking on another project.. but he was very reluctant, after all this was his personal bike. His excuses included that he couldn't be in the BMW clubs if he gets rid of it. But, he hadn't ridden the thing since ~1981, so I was a bit anxious. Well after 2.5 years of consistent reminding, on June 11, 2007 he came outside while I was cutting his grass. He asked if I was still interested in it.. I lit up. Sadly for me, he said that the guy who just remodeled his house said he'd buy it for $1200 cash. Ugh. That's a bit high of a price for the condition, I thought. I got to thinking about it, and I figured what-the-hell.. I told him I'd give him $1000 that day. He said $1100, (which he needed as downpayment on his new BMW R1200RT)!). I told him I'd get it to him by next Monday. He said he wanted the bike gone, out of sight, so when the remodeler comes around, the bike wouldn’t be there any more. I decided to cut my work day short, so 2 hours later, and: Here are some detailed shots: ..and here's the loot: The bike, the bags... fairing lowers, 2 complete headlight assemblies, the stock gas tank (in great shape), new-in-box bulbs and filters and oil pan, extra mirror, extra turn signal housing, BMW crash bars, random old motorcycle literature, and some other odds-n-ends. I reunited the two bikes: The happy new owner: Its new home: A mini-tear-down begins: I started doing a minor tear-down/preparation. Whilst performing the last step of the day - an engine oil change – the old style rubber o-ring that goes between the filter and the 'cap' (which on newer filters is now built in) slipped out of my oily fingers and down into the block/pan. Well, what do I do? I was talking to my moms... boyfriend-guy-whatever, and he said he'd just go on with the project and start 'er right up. I personally didn't think it's a good idea. So, fearing what I might find, I dropped the pan and cleaned things out a bit. Back to the original post... After waiting months(?!) for a damn oil pan gasket to arrive, it showed up and it was time to put together my R90 and see if I could get it to turn over. It needs a full overhaul, but I am a broke(!) dumb kid and I have too many other projects going on right now. Well, I decided to actually follow the directions on the gasket sealer, and wait 24 hours after hand-tight assembly to actually torque it down. The Clymer said tighten it "securely." Well, what does that mean? I like actual numbers, so I guessed and made corrections to a torque wrench to get to a "secure" feel. Right as I approached it.. THWACK! There goes one of the bolts. ARGH! I freaking took all the 13 other bolts out, dropped the pan, but ah ha! Good luck, a lot of the bolt was still sticking out, and even better... I could unscrew it with my fingers. So, it all went back together. I filled it up with oil while I was installing the carbs. I hooked it up to a battery charger, and got the starter button to work finally. But, I head crackcrackcrackcrackcrack when I press it. Hmm.. did it seize up? I am pretty sure I could turn 'er over with the kick start. So, I try the kick start. It's not going ANYWHERE. Damn it. So, I pull the clutch and try the starter button. Now it's just bogging down instead of crackalacking. It's still not turning over. So, I pull the clutch and the kickstarter can swing down now, too.. but that doesn't turn it over, and there's little-to-no recoil. Damn. Transmission problems too. So, I figure I'll just bite the bullet and remove the transmission. A nut holding down the battery box is so stripped and rusted, I have to remove that mount with the box. I use my own judgement, and a little bit of the Clymer, on how to get the transmission off but the bolts securing the drive shaft to the output are like 12point(?) or something funky. I have 12point sockets/wrenches, but they just don't feel right on it. In the pic in the Clymer they look like typical 6point. I also noticed this crack. It doesn't actually turn right again (as the picture looks); it just runs along the "grain" for an inch. Damn. I was trying my tools on those output bolts, but they weren't budging. Well, it was getting late and I had reached a stopping point on my project, so I looked for something else to do for a bit. Ah ha! Why not make my own modified 27mm swingarm socket? Screw buying one. I turned this: Into this: I made a boo-boo on my original mental design, but I knurled it just for show. ..and it fits! Well, I'm sure there's more I've got to say, but I've got questions. What do you think about the transmission? What do you think about the bolts? Other advice/thoughts?