Airhead "Tips and Tricks"

Discussion in 'Airheads' started by elmoreman, Sep 26, 2006.

  1. Disston

    Disston ShadeTreeExpert Supporter

    Joined:
    Aug 31, 2009
    Oddometer:
    19,057
    Location:
    Silver Spring, Md
    It is your perfection that will lead to your downfall, Plaka.
  2. Plaka

    Plaka Brevis illi vita est

    Joined:
    Jun 19, 2010
    Oddometer:
    9,173
    Location:
    .
    my downfall is long in my past Disston.
    Disston likes this.
  3. BJMoose

    BJMoose that trick never works Supporter

    Joined:
    Oct 15, 2018
    Oddometer:
    1,009
    Location:
    Hamilton Montana
    Plaka, how about: bin down so long - looks like up to me?
    Plaka likes this.
  4. arbalest

    arbalest Long timer

    Joined:
    Mar 19, 2009
    Oddometer:
    1,517
    Location:
    Windham, Maine

    I'm so far down, I have to look up to see bottom.
  5. CNRED

    CNRED It'll be OK Supporter

    Joined:
    Feb 17, 2008
    Oddometer:
    1,048
    Location:
    Scottsdale, AZ
    Such a happy place....
    TommyCareless likes this.
  6. TommyCareless

    TommyCareless Break Down Connoisseur

    Joined:
    Jan 29, 2015
    Oddometer:
    504
    Location:
    Ole Brunswick, Atlantic Canada
    My favourite comedy duo !
    ~T
  7. Steamdonkey

    Steamdonkey Adventurer

    Joined:
    Apr 23, 2021
    Oddometer:
    27
    Location:
    Vancouver, Canada
    I’m with The DA. I’ve taken my tank off a dozen or more times and always have to pry and pull and twist on the fuel line at the petcock ribs (running wires, rebuilding MC, adjusting brake line tension, cleaning corroded frame under leaking MC, replacing failed electronic ignition, etc). I’m more afraid of snapping the plastic petcocks than anything else. Love the washer idea. I can see how the quick disconnects I’ve seen on the web would be too long for the space allowed but it would be nice.
    SmittyBlackstone likes this.
  8. Plaka

    Plaka Brevis illi vita est

    Joined:
    Jun 19, 2010
    Oddometer:
    9,173
    Location:
    .
    Just make sure the washer is facing the right way around or it will screw up the petcock nipples.
    SmittyBlackstone likes this.
  9. 100RT

    100RT Long timer

    Joined:
    Nov 4, 2009
    Oddometer:
    1,976
    Location:
    NEWTON FALLS, OHIO
    That happened to me years ago, I bought new petcocks with the metal ends.
    SmittyBlackstone and Steamdonkey like this.
  10. Tripletreat

    Tripletreat Long timer

    Joined:
    Dec 20, 2008
    Oddometer:
    1,211
    Location:
    Boise, Idaho
    Were the final airhead gearboxes manufactured with the infamous circlip, or did BMW save those 50 pfennings until the very end of the line?
  11. Disston

    Disston ShadeTreeExpert Supporter

    Joined:
    Aug 31, 2009
    Oddometer:
    19,057
    Location:
    Silver Spring, Md
    If '95 is the last year of Airheads the circlip came back sometime in '94. But it is a little more confusing and it seems the change either way, in the beginning or the end, the lines are not hard. I think if you have a '95 you can be pretty sure you have the circlip. If you have a '94 it's iffy. Some don't believe either way until they open the box.

    Snowbum did a big survey on boxes that were opened and recorded trans serial numbers of which is which. To really get into that check out Snowbum's Tech pages.
    SmittyBlackstone likes this.
  12. Steamdonkey

    Steamdonkey Adventurer

    Joined:
    Apr 23, 2021
    Oddometer:
    27
    Location:
    Vancouver, Canada
    it’s also occurred to me from reading all the input that maybe I have 1/4” line and not 7mm. I need pliers to twist the lines off the petcock nipples (more nipples than pornhub here these days)
    SmittyBlackstone likes this.
  13. 100RT

    100RT Long timer

    Joined:
    Nov 4, 2009
    Oddometer:
    1,976
    Location:
    NEWTON FALLS, OHIO
    A dab of silicone grease helps them go on and off the metal nipples.
    JZed and SmittyBlackstone like this.
  14. Steamdonkey

    Steamdonkey Adventurer

    Joined:
    Apr 23, 2021
    Oddometer:
    27
    Location:
    Vancouver, Canada
    Thanks, 100. I just bought some braided 7mm hose from a BMW shop and it is different than what I have on now. The PO must have switched all the lines to 1/4”.
    SmittyBlackstone likes this.
  15. Plaka

    Plaka Brevis illi vita est

    Joined:
    Jun 19, 2010
    Oddometer:
    9,173
    Location:
    .
    I only use 1/4 inch and it is indeed tight. use washers at the tank. When I was running saddle tanks I got a pair of hose pliers because there were so many connections.

    The braided 7mm is used on vintage VW's and an online VW place might have it a lot cheaper than BMW.
    SmittyBlackstone likes this.
  16. Runaway Train

    Runaway Train The Left-Right Tourer

    Joined:
    Aug 9, 2013
    Oddometer:
    647
    Location:
    Ontario, Canada
    My February 93 did not have the circling or the groove.

    (Damn you autocorrect..."circlip")
    SmittyBlackstone likes this.
  17. Uke

    Uke visualist Super Supporter

    Joined:
    Oct 9, 2013
    Oddometer:
    6,337
    Location:
    HouTex USA
    Nor does my '93 R100R, I think you have to get well into the '95 model year to find the return of the factory circlip.

  18. Thomaspin

    Thomaspin Been here awhile

    Joined:
    Feb 21, 2019
    Oddometer:
    110
    Location:
    Scottsdale, AZ
    My brake and clutch levers at the handlebars developed significant vertical slop. Understandable after tens of thousands of actuations. This is on my 1975 R90/6 with 75,000 miles, a daily rider.

    These levers pivot on nylon bushings, identical on both sides. The pivot bushings are originals which came with the bike when new. The full p/n is 32 72 1 232 662. The fiche suggests that the same part was used from /5 though the end of Airhead production, but check before ordering:

    image2-1.jpeg

    Removal of the clutch lever is simple. Release the cable at the gearbox, then at the lever, be sure not to lose the brass ferrule which goes over the nipple, unscrew the 10mm bolt, push out the pivot pin from below and the lever comes out. On my /6 the brake lever needs a little more work. First, loosen the adjuster on the under tank ATE brake fluid reservoir and release the cable. The large screw for the throttle cam assembly at the handlebar is then undone, the cover plate removed after sliding back the protective rubber sleeve for the throttle cables (32 73 1 230 037 - probably a good time to renew it), and the cam assembly moved out of the way. The slotted pivot screw can now be accessed from above, with a 10mm socket below.

    You can force out the old bushing with the new one - I use a soft blow hammer over a workbench with a hole in it, but a C clamp with a small socket on the receiving end would work as well. Here's the old bushing partially pushed out by the new (right) - it's a tight friction fit:

    image0.jpeg

    The new bushing in place on the brake lever. The arrow denotes the wear caused from the slop in the lever, which allows the land area to abrade the inside of the lever housing. I generously grease the receiving hole for the brass cable nipple before reassembly:

    image1.jpeg

    Here's the old bushing - 46 years on it:

    image2.jpeg

    Curiously, it measures the same as a new one, meaning 11.5/8.0mm OD/ID, suggesting that the cause of the slop is deterioration and softening of the nylon, not loss of dimensional integrity. The difference is night and day, with near zero slop at the end of the lever, compared with 3-5mm either side of center with the old bushings.

    While the fiche shows the pivot pin is secured with a star, toothed washer and nut, I dislike star washers for the damage they cause to metal, preferring a wave washer and a new nylock nut. The latter are not reusable. The latter is tightened just enough to prevent binding of the lever with no cable attached. While the bushing nylon should be 'self-lubriacting', whatever that means, a touch of bearing grease does no harm on the pivot pins before reassembly.

    This is also a good time to check the felt rings on the cables are present and intact - they nestle inside the adjusters at the handlebars and at the brake fluid reservoir. P/n 32 72 1 231 610. You need three.

    Attached Files:

    globalt38 and brittrunyon like this.
  19. Disston

    Disston ShadeTreeExpert Supporter

    Joined:
    Aug 31, 2009
    Oddometer:
    19,057
    Location:
    Silver Spring, Md
    In the past some riders have found new bushing will be too tight. Not having the proper sized honing tool they have honed the bushing with a drill bit.
    SmittyBlackstone likes this.
  20. mslim

    mslim Long timer

    Joined:
    Jan 11, 2015
    Oddometer:
    1,876
    Location:
    Austin of the Ozarks
    Yes I did this with my bushings as a field expedient method. It worked OK but I picked up this cheap reamer on Amazon for the next Tech day.

    [​IMG]