RS Resuscitation

Discussion in 'New Zealand' started by Box'a'bits, Dec 4, 2013.

  1. Box'a'bits

    Box'a'bits In need of repair Supporter

    Joined:
    Sep 26, 2008
    Oddometer:
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    Background to the thread:
    I bought the RS in London in Mar 1990. I am the 3rd owner from new. The other 2 did about 25k miles on it. I met the 2nd owner sometime later. He was a nice guy, working as a Vehicle Tester at one of the MoT testing stations I went to. He traded the RS on a K1, & was nice enough to give me several original bits from the bike that he still had stashed under his workbench.

    The bike is a '78, manufactured Dec '77 according to the VIN no info. We bought it from Park Lane BMW (but they had it parked several buildings away from their main floor, & buried in the depths of an underground carpark). We bought it to tour Western Europe for 5-6 months starting with France, Spain & Portugal. We wrecked a rear wheel bearing in Spain, & struck alternator issues (diode board) on the return leg via Holland. Unfortunately the alternator fault meant we couldn't sell it to buy plane tickets home. As a result we ended up staying in the UK for far longer than we'd initially expected (3 years). That worked out well though.

    Between that & the next tour we got a Corbins seat (the stock seat with first aid kit underneath was good for about 60 miles before you had to get off), tried a higher screen (ditched), better grips (the standard BMWs were squarish & ridged, & hurt your hands on a long ride), koni dial-a-rides, a fork brace, a surefoot side stand, stainless exhausts, & braided brake lines

    [​IMG]

    The following year we did a tour of Ireland, Scotland, Wales, & England, including a couple of weeks in the Isle of Man.

    [​IMG]

    We were planning a final trip the next year through Africa, but a bankrupt disqualified driver, driving an uninsured van (that belonged to some else) wrecked the RS & injured me, so that was that.

    [​IMG]

    The consolation prize was a ride on the now naked RS thru’ Scandinavia, down thru Germany, Switzerland, & France. There was a massive storm in the south of France, we got flooded out, & 50 people were killed. We fled back to the UK, dropped the RS to a Logistic Co to be shipped back to NZ, then flew to Florida in time for Hurricane Andrew, & onto Hawaii, which had had its own Hurricane issues. We called that trip the ‘storm capitals of the world’ tour.

    [​IMG]

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    Once the RS made it back to NZ it sat in the shed while the R80ST got ridden. Eventually we registered the RS, partially repaired the fairing for a Rusty Nuts 1000 mile challenge & rode it.

    [​IMG]

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    The flywheel was lightened, I dropped an Enduralast alternator into it so I could boost the lighting for the 1000 milers, & an oil cooler was added, seeking to reduce pinking on hot days (which we don’t really get a lot of in NZ).

    I sold it to friends for $6.5k in about 1996, bought an XR600 for $2k, traded that on a $3.5k R65k, & finally traded that on the RS (less panniers) back 12 months later.

    For about a decade (during the 2000’s) the bike was hauled out to do 2-3 rides a year (Cold Kiwi, CDMTC toy run, & a Manfield track day in Jan. It still got a fair wad of cash thrown at it. It got a new driveshaft in 1999 when a vibration indicated a UJ was on its way out. I spent the 2005 bonus twin plugging the head, getting unleaded seats installed, new valves, 1st oversize pistons & rings, & also replacing all of the discs, which were badly worn & had started to crack. I also replaced the headers after putting a big flat in the left side avoiding a slip coming back from the Cold Kiwi. A big rock still managed to bite me…

    Finally in 2009 the RS was a retired to the side of the garage, pending exploration to find out where a fairly annoying oil leak was coming from. .
    #1
  2. Box'a'bits

    Box'a'bits In need of repair Supporter

    Joined:
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    Oddometer:
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    Unfortunately when Gus came on the scene it became too easy to use the RS for a parts bike.

    It took me a while to find out where the oil leak was coming from. The initial suspect was the main seal. However it turned out to be a split in the gearbox flange, possibly dating back to the London accident. The cover was replaced, & while work was being done, the gearbox was overhauled with new bearings & seals.

    [​IMG]

    [​IMG]

    Before the gearbox could be installed in the RS, Gus’s box had issues, so I did a clutch pack & gearbox transplant. That turned him into no stall motor – perfect for slow going & snotty hills.

    I finally got around to fixing Gus’s gearbox in Sept / Oct this year, so have been progressively working to get the RS running. In recent months I have:

    1. Reinstalled a stock alternator. The RS had an Enduralast Constant Magnet alternator, which I have stolen for Gus. So Gus’s alternator has gone into the RS;
    2. Reinstalled the Oil Cooler. The lines were pillaged to act as a pattern for Gus’s lines (see a theme here?). Unfortunately the Hydraulic Lines place misunderstood what was required & cut the originals up;

      [​IMG] [​IMG]
    3. Reinstalled the Bosch starter, which…
    4. Replaced the main seal & oil pump seal, mainly as a precautionary measure;

      [​IMG]

      [​IMG] [​IMG]
    5. I oiled the bores to free the pistons, then have spun the motor to get the oil circulating
    6. Reinstalled the clutch & gearbox.

      [​IMG] [​IMG]
    7. Rebuilt the carbs, given I had scavenged some jets from them for Gus, & also there was an expectation they might be gummed up.

    Over the last couple of days I have completed the preliminary reassembly of the RS. The idea has been to get it together, fire it up & run it to find out what the issues are.

    [​IMG] [​IMG]

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    Last night I fired it for the first time in 5 years. Initially it just cranked, & wouldn’t fire. I discovered that fuel wasn’t getting to the carbs – I need to pull the petcocks off & ensure the sock filters are clean.

    The battery (from Gus) is on its last legs, so I needed to use a jump from the car. Once started (and the oil smoke cleared from the squirts I had pumped into the bores) it settled down to a smooth idle. Putting it into gear was more problematic. I did an inadvertent 30 second burn out on the garage floor when the clutch was further out of adjustment than expected. Lucky I had the front brake on.

    Then I took it down the driveway to give it a quick wash. Of course the battery decided to die at the low point on the driveway. Wouldn’t start even with a jump from the car. And it started to rain... :fitz

    Thing I need to work on:

    • Alternator – no charge. Obviously I haven’t got that right yet;
    • Rear brake. No fluid (where did that go) or pressure. The brake switch is on all the time.
    • The RS had a K&N filter. I’d like to go back to the stock filter.
    • Centre stand. It over extends, & is a pain to get on & off the stand. I need to weld a stop on.
    • After putting everything together I realised I had neglected to change out the Paralever gearbox seal. I'll need to disassemble & replace that.

    So today I bought a Motobatt MBTX30U battery ($226 at 'The Battery Cell', Petone), so the electrical system is more stable as I chase the charging issue. Hopefully that will be straight forward.

    [​IMG] [​IMG]
    Does my battery look big in this?

    The Motobatt appears taller than the stock battery, as the battery strap knurled nuts just aren't able to thread onto the stays. But not as wide, so easier to get the battery into the cradle.
    #2
  3. Box'a'bits

    Box'a'bits In need of repair Supporter

    Joined:
    Sep 26, 2008
    Oddometer:
    4,391
    Location:
    Wellington, New Zealand
    New parts list:
    Air filter
    Oil filters
    Gearbox seal
    Grips
    Gear change seal (for Gus)

    To do:
    Fix charging / Alternator
    Fix rear brake
    Seat recover & base amendment
    Paint & tidy sub frame
    Clean up stained stainless exhaust
    #3
  4. Mark_S

    Mark_S Fair Weather Faggot

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    Location:
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    I thought an RS had a sportier fairing than that?
    #4
  5. Padmei

    Padmei enamoured

    Joined:
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    Nelson New Zealand
    looks like it has given you a lot of adventures & a lot of trouble - the best bikes are like that:D
    #5
  6. Left Testicle

    Left Testicle Been here awhile

    Joined:
    Jun 14, 2013
    Oddometer:
    450
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    New Zealand
    geez I see u capital city turkeys are getting rogered for a battery. only $170 in the 5th biggest city. had me concerned when u said u bought from Park Lane BMW. I parked a 77 model outside in October 1987 and shipped a new one home.
    remind me not to ride with you. sound like a moving disaster area
    #6
  7. Box'a'bits

    Box'a'bits In need of repair Supporter

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    Trolling the net indicated best price was $211 + free freight, but given past issues with batteries, I went local so I can claim on the warranty if it craps out.

    Only ever had three accidents on the road.
    • Just after my 21st birthday a pedestrian stepped out in front on me. In braking to avoid her, I hit a painted white arrow. Unfortunately it had just drizzled shortly before that, lost the front, & went down. She disappeared. I did some knee damage that still troubles me;
    • The London incident. 2 lanes of traffic coming up to traffic lights. Van in the left, I was coming down the right. The van decided to flick down an alley on the right, across the 3 lanes, & collected me. Dislocated a collarbone;
    • Chasing a friend across the Rimutakas on semi knobbie's. Lost the front end on a pothole when cranked over. Did my 1st rib on that one.
    Off road step offs don't count.

    Oh & wrote off mum car when I was 17 or so. A guy just outside Levin went to sleep at the wheel, & took us out (we were coming the other way). It was at night. He came over the brow of a hill, then his lights disappeared.

    How the G/S coming along?
    #7
  8. Steve in NZ

    Steve in NZ scared/cheap

    Joined:
    Aug 27, 2001
    Oddometer:
    1,066
    Mechanic has rebuilt carbs but keeps getting other regulars arriving with bikes that need fixed and then adding more jobs for the summer series or speedway bikes.

    i am no fussed. Its my 50th birthday present to me, so he has some time to get it up and going for that date to roll around. Did a bit of research.Got a post in Airheads section.

    Lets put Marzoochi stickers on White Power forks. Mechanic guessed they were early 90s KTM forks. Close but they are off a Husaberg.
    #8
  9. Box'a'bits

    Box'a'bits In need of repair Supporter

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    My 50th next month. I get to paint the house. Oh happy days! :nah
    #9
  10. Steve in NZ

    Steve in NZ scared/cheap

    Joined:
    Aug 27, 2001
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    1,066
    should of bought brick:rofl
    #10
  11. Kokopelli

    Kokopelli Yeah, right!

    Joined:
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    Rolleston
    Stay off that ladder and especially the car port roof.

    By the way, to make you feel better, I wiped out on my way home on Wednesday, while turning onto a motorway on-ramp. Still sore and a little bruised, but uninjured. I was back on the bike before anyone could get out of a car. It was just a greasy wet road, and my mind was somewhere else. Maybe it's finally time for a new helmet.
    #11
  12. Voltaire

    Voltaire Titanium and Ceramic Hipster

    Joined:
    Jun 4, 2011
    Oddometer:
    2,589
    Location:
    Auckland,New Zealand
    Cool pics, Snowing in London don't happen very often. I was coming back from the Elefant treffen and it was like that in London for about a week.... thinking Feb 1991?
    Did you ever go to the BMW meetings at a pub in Putney?
    I bought a R100 RS V reg at World of Wheels in Clapham in 1991 and used to go to Bob Porchreas ( spult rong) for stuff.
    #12
  13. Box'a'bits

    Box'a'bits In need of repair Supporter

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    Yes, regularly went to the BMW meetings at Putney, & did all the bike shopping at World of Wheels. The screen & seat came from Bob Porecha. The photo is probably from Feb 1991. The seat had leaked & then it froze solid for that week. I tried to ride the bike into work in town (because it had an underground carpark) - it felt ridiculous because I was seated higher than I was used to. .
    #13
  14. Box'a'bits

    Box'a'bits In need of repair Supporter

    Joined:
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    The most pressing jobs to do on the RS are:
    • Get the front brake switch working (always on a present).
    • Sort out the alternator charging (it isn't)
    • Stop the clutch lever dumping out gear oil.
    Todays job was the front brakes. Dropped out the fluid (still clean, but now a few years old). The switch is a pressure one, so I needed to empty the master cylinder. While I was the I decided to check the master cylinder seals (starting to get scored, but the bore still appears acceptable) & the caliper seals (age hardened & starting to split. The pistons chrome is starting to rust / flake on the outer edges, & probably needs replacement.
    <table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/KLH48nQwcBjHQUvVUj5rCdMTjNZETYmyPJy0liipFm0?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-_DO5JjMkrJI/UruhPh96j_I/AAAAAAAAPgA/D2ulcatpARA/s800/P1010338.JPG" height="577" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/111498450837388124928/BMWR100RS?authuser=0&feat=embedwebsite">BMW R100RS</a></td></tr></table>
    <table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/Bpktyai-tGe7T5vVSN45mNMTjNZETYmyPJy0liipFm0?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-5R6r60u10Z8/UruhS0O8b0I/AAAAAAAAPgY/Hye_qAeAm2A/s800/P1010342.JPG" height="577" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">From <a href="https://picasaweb.google.com/111498450837388124928/BMWR100RS?authuser=0&feat=embedwebsite">BMW R100RS</a></td></tr></table>
    Order in with Motobins.
    #14
  15. Mark_S

    Mark_S Fair Weather Faggot

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    none of this looks like a paint brush
    #15
  16. Manakau.KTM

    Manakau.KTM Been here awhile

    Joined:
    Mar 3, 2012
    Oddometer:
    905
    Location:
    Horowhenua NZ
    Hi Steve

    [​IMG]

    Took this out today. Give me shout when you are on the road again. Two sad old bastards must be better than one.

    Cheers

    Wayne
    #16
  17. Padmei

    Padmei enamoured

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    Nelson New Zealand
    That ST on tme - if one was to do a front end swap from a GS (or an unholy union) you'd get a G/S? No differences in the rear end suspension?
    #17
  18. Box'a'bits

    Box'a'bits In need of repair Supporter

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    The main differences are:
    • Front light (taken from an R65), indicators, & tacho (the G/S didn't have one);
    • Front suspension;
    • Rear suspension (shorter);
    • Oil pan is standard - no provision for the G/S pie plate bashplate;
    • Chromed crashbars;
    • Chromed exhaust (the G/S was black painted);
    The frame, engine, & drive train are all the same. :D
    #18
  19. Box'a'bits

    Box'a'bits In need of repair Supporter

    Joined:
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    Slow progress on the RS

    Replaced the seals in the front calipers &#8211; these were age hardened & splitting. The pistons were rusted, & wouldn't retract properly. The dust seals were completely ruined. They have steel inners to keep their shape, which split as soon as I looked at them. So I&#8217;ve replace all of those. The new dust seals were a bit more than difficult to install. I think I&#8217;ve wrecked one, being overenthusiastic trying to get it to sit flush. Oh well, an issue for another time.

    [​IMG]

    [​IMG] [​IMG]
    Would you trust your ability to stop to these?

    I had to place another order for the hydraulic brake light switch. I forgot to get this with the caliper seals. It&#8217;s installed now, though.

    The gearbox piston seal is a right bastard to slide on. To install it requires it slide over quite a sharp edge. The seals are quite &#8216;plastic&#8217;, so not a lot of give. I split the 1st one I&#8217;d bought, & needed to order another. A bit of annoying if you have to order from the UK. Now replaced. I put a bit of electrical tape over the sharp edge, warmed the seal, then eased it over.

    [​IMG]

    The sump gasket has dried out, & there has been a reasonable sized puddle of oil under the RS. I sort of expected that. I ordered in a couple of sump gaskets & have replaced it.

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    Quite a bit of sludge on the sump, but given the bike has been sitting 5 years...

    [​IMG]
    Betterer...

    The charging fault turned out to be that I'd reversed these 2 wires.

    [​IMG]

    I have had a look at my spares supplies & have built up quite a little Emporium. But as always, the seal you actually need, you never have.

    I need to have a look at Igor&#8217;s R80 to see what we need to do to get that running. I'm trying to get EddieB interested, & it'd be easier if it ran.

    And I need to start to clean up the bent bike, so I can see what&#8217;s up there. Talking of which I started it tonight. The battery was flat, so I swapped in Gus&#8217;s one. Clouds of smoke initially, & running heavily on one, because it had just been slapped back together by the Mechanic in Auckland, & he&#8217;d caught one of the throttle cables putting the tank back on. Fuel everywhere from a dodgy fuel line, which needs to be replaced. But overall happy. I&#8217;ll likely start a new thread on that.
    #19
  20. Mark_S

    Mark_S Fair Weather Faggot

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    so you'll have 3 build threads going plus be dabbling with Igors R80????
    #20