BMW r90/6 cafe racer build

Discussion in 'Airheads' started by Hearse, Nov 10, 2012.

  1. disston

    disston ShadeTreeExpert

    Joined:
    Mar 22, 2011
    Oddometer:
    12,375
    Location:
    Silver Spring, Md
    There is a thread here just recently where one of the proficient mechanics found there was a difference in a pair of Ate calipers. His is apparently the only instance of this known to happen. I can't explain it. So I will now give you the stock answer we have used for so many years. Just use your eyes and report if this looks like it has problems when you do this, OK?

    The calipers are two sizes. A single disk set up should have a 38mm caliper and said caliper is not marked with the number. A dual caliper set up should have two (2) 40mm calipers and they should be marked with the number 40 on the outside round portion of the caliper. This is visible with them mounted on the bike. Very few exceptions to this note, if any.

    How ever since the bikes are now what we call vintage many times the OEM equipment has been moved around. You can even occasionally see a dual set up with one of each. Since you are building your own you could use 40 or 38 calipers I suppose.

    The calipers are movable from side to side. There are two (2) holes in each caliper. One for the brake line, on the bottom. And one for the bleeder screw on top. Swap this function to make caliper work on what ever side you like.

    Th problem another inmate had was the taper at the bottom of one of these holes did not accept the bleeder screw so he couldn't move a left caliper to the right side. He fixed it. But it is also the only time any body remembers hearing this problem I think.
    #81
  2. Hearse

    Hearse Project n'gagi

    Joined:
    Nov 7, 2012
    Oddometer:
    148
    Location:
    sydney
    ah excellent!!

    It's half weird because I had a 40mm fitted stock to my r90/6 and I got another 40mm delivered - and its interchangable as you said above, so YEW! Two 40mm callipers which will work great

    It's only 0716 this morning so I'll call the guy a bit later to get my different leg sent down :-)
    #82
  3. Hearse

    Hearse Project n'gagi

    Joined:
    Nov 7, 2012
    Oddometer:
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    sydney
    got my powder coating back guys...I am 'happy' in the sense that it looks great and I know it will last....but there were some things that didn't make me 100% happy - before I got it done I asked the normal stuff, couple of them being "please mask off bearing housing's and the ID plate etc"

    Whole frame...
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    Stainless bolts - I have a whole SS kit for the bike. Using copper grease as an anti seazing agent
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    bearing housings with PC in them :( would i just scrape the PC out?
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    ...he was close with the ID plate, just not quite there...heh. I'll just cut around the edge of the plate and peal the PC off
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    When i get my lower fork slider this week - I will hopefully be able to build the bike in to a roller this weekend/week ahead. YEW!
    #83
  4. Fast Idle

    Fast Idle Since the Sixties

    Joined:
    Nov 9, 2012
    Oddometer:
    503
    Location:
    The Great Land
    Powder can be really tough. If it doesn't come out easy I would mask it off really, really good, multiple layers, including a tarp or something over the whole bike frame ( because I have accidents from time to time) and use paint stripper to soften it. That will make the scraping easier and prevent damage to any machined surface. Should go fairly quick that way. Wipe away any residual stripper with paper towels and water wash a couple times with a bucket & rag. Pull the mask as soon as your done That's for the steering head. You'll just have to try your luck on the ID plate. Looks like they blasted part of it. I'm in the middle of my own R90/6 rebuild. A complete including engine and transmission overhaul. More stock than cafe though. :1drinkGreat thread!
    #84
  5. Hearse

    Hearse Project n'gagi

    Joined:
    Nov 7, 2012
    Oddometer:
    148
    Location:
    sydney
    Hey Fast

    Thanks for the hints mate.

    Yea i will have to look in to it, see how we go in getting that crap off...pretty pissed with it eh.

    Anywho...

    Mate good luck with your build. I am loving every minute of my build! So much fun. I figured if in the near future my engine goes to shit Ill get one of those upgrade packages from motobins to make it 1000cc :) :)

    .... but ill cross that road when i get to it.

    Cheers,

    Warren
    #85
  6. Fast Idle

    Fast Idle Since the Sixties

    Joined:
    Nov 9, 2012
    Oddometer:
    503
    Location:
    The Great Land
    For sure, building the bike is great! My transmission is finished. Working on the engine now. She was a little ruff when I brought her home. It's fun to follow builds like yours and others. Gives me lots of ideas for my bike!:1drink
    #86
  7. Hearse

    Hearse Project n'gagi

    Joined:
    Nov 7, 2012
    Oddometer:
    148
    Location:
    sydney
    Hey guys!

    So I did a couple cool things this weekend...

    First I re-spoked my wheel with brand new SS spokes
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    The complete wheel fitted with second disc AND my brand new Avon RoadRiders - SUCH a mint set of tyres
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    Then I started to re-assemble my rear end, rebuild the swing arm with all new bearings/seals/bushes and mounted it to the frame, then rebuilt the rear wheel with all new bearings/seals etc and mounted that too, with my brand new Hagon Shocks
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    THEN - get on to this, I did my stripes on my tank/seat. They are 2.5 inches wide total with all three stripes, I reckon they look perfect? Just have to do the front of my tank, need to trip the decals to get them under the fuel cap
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    Just need to finish my tank decals, and get my front end rebuilt this week/weekend to have it in a roller. So excited boys.
    #87
  8. brothermosley

    brothermosley Motorcycle Operator

    Joined:
    Mar 10, 2007
    Oddometer:
    624
    Location:
    Medford, MA
    Very sharp! Keep it coming :clap
    #88
  9. kaput13

    kaput13 gasoholic

    Joined:
    Nov 20, 2010
    Oddometer:
    668
    Location:
    South Florida
    Your day glow boxer is looking good Hearse. Can't wait to see the entire bike. Did you give up on the snazzy fuse and wire connector gizmo?
    #89
  10. Travmoto

    Travmoto almost there...

    Joined:
    Nov 17, 2009
    Oddometer:
    222
    Location:
    QLD, Terra Australis
    This is an awesome thread, loving your bike mate especially the colour!

    I'm just hanging to get my wedding/honeymoon out of the way so I can do something with my r100..... this build is good inspiration
    #90
  11. Hearse

    Hearse Project n'gagi

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    Location:
    sydney
    Thanks heaps BM.

    Yea gave up on it, I couldnt justify the $300 price tag, I put that money towards a twin disc upgrade instead.

    Thanks heaps Trav, loving it too eh, a lot of hard work that reaps nothing but rewards. Its going to be great riding this around Sydney....should turn heads hopefully :)

    Are you turning your R100 in to a cafe or resto project?

    Cheers,

    Warren
    #91
  12. Les_Garten

    Les_Garten Been here awhile

    Joined:
    Oct 6, 2011
    Oddometer:
    744
    Location:
    PSL, FL
    You can do the wiring thing later.

    I put it on my dream list, thanx for that reference.
    #92
  13. Travmoto

    Travmoto almost there...

    Joined:
    Nov 17, 2009
    Oddometer:
    222
    Location:
    QLD, Terra Australis
    I bought the bike from japan ('88 R100RS) with the intention of turning it into a bobber. The only problem is its too nice.... original 32000km, original toolkit etc in place, pretty good paint etc. Got it registered the day after getting it and been loving it. The fairings not really made for my size though (6'2in) my knees hit and the wind blast gets me right in my mouth lol.

    I put six months duel rego on it so I will see how I feel then about it.
    #93
  14. Hearse

    Hearse Project n'gagi

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    Nov 7, 2012
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    Les - yea mate I think its a wish part, I'll look at it later. I am happy with the stock setup

    Trav, mate I'm 6'4 - hoping i fit nicely on my beast when its all setup. Got my rear sets etc so should be right.
    #94
  15. Hearse

    Hearse Project n'gagi

    Joined:
    Nov 7, 2012
    Oddometer:
    148
    Location:
    sydney
    Hey guys, i missed a week of updates (away on a waterpolo tour) but im back...with SOME updates

    So I have put my forks back on - rebuilt the forks with all new seals/washers etc. As you can see twin disc upgrade :)
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    Then this is my favourite part - the Gorilla decals. Seen as its "project n'gagi" which means silverback in Swahili I thought it would suit! And i love gorillas
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    This is me with the Gorilla's in Rwanda - bad ass!
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    I did my front fender and bikini fairing - its only the colour layed and i will do the clear in a couple weekends when i clear over my decals on my seat and tank
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    #95
  16. Hearse

    Hearse Project n'gagi

    Joined:
    Nov 7, 2012
    Oddometer:
    148
    Location:
    sydney
    This weekend i put my heart back in the body. the engine is in :) I upgraded the ignition system, i put on my seat tray and my fender eliminator :) you might be able to see the seat tray has a slight bow in it - just to accommodate the random possibility of the wheel bottoming out.

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    This week I will be rebuilding my wiring harness (keeping the stock one in tact for future use if required) mounting my battery under the seat and all the other electronic components...

    oh and sourcing some more decals for the front fender and bikini fairing (electric orange decals to tie my front fender and bikini fairing in to my bike)
    #96
  17. Djedi

    Djedi Airborne Airhead

    Joined:
    Mar 16, 2013
    Oddometer:
    8
    Location:
    San Diego
    Fantastic build, man! A real inspiration!
    Cant wait to see her all back together.
    #97
  18. SERE Nate

    SERE Nate Been here awhile

    Joined:
    Jan 31, 2013
    Oddometer:
    123
    Love this build! Looking forward to updates.
    #98
  19. Travmoto

    Travmoto almost there...

    Joined:
    Nov 17, 2009
    Oddometer:
    222
    Location:
    QLD, Terra Australis
    yup keen to see how its coming along
    #99
  20. Hearse

    Hearse Project n'gagi

    Joined:
    Nov 7, 2012
    Oddometer:
    148
    Location:
    sydney
    Hey guys,

    Been working on the electrics on the bike - taking my time trying to get it just right...its hard keeping it neat under the hump, but it's getting there.

    So all wires are run from back to front, hidden, and battery is connected, alarm has been wired in etc
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    At the back I have a key that will bypass the alarm unit if it were to fail...I know, I know it's easy to bypass but if you didnt know it was there one wouldnt know about it
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    Cables run under the seat/frame
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    The headlight bucket - SLOWLY getting there, slowly! Such a messy place to be :)
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    Oh and here is my headlight brackets to hold the bucket, nice stainless
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    I built a little bracket to host my Acewell and two switches, lights on/brights and a kill switch
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    I got my boxer metal rear sets on as well!
    Clutch
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    Brakes
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    It is a bit messy but it all works! When the wire work is done under the seat it will look neater.

    Next step (hopefully tonight) I'll run my wires through my left handlebar to get the horn and indicator buttons working and then run the two switches under my acewell to the headlight bucket as well...yew. Hopefully more pics to come tomorrow...and better ones.:D