Motor and Wheels

So another pretty common question going around the Beemerverse is, “What spine lube do I use?” The most common answer: Honda Moly 60. You can get this stuff at pretty much any Honda bike dealership. Funny story… I went in and grabbed some and the guy behind the counter was like… “What do you people do with this stuff? You BMW guys… ” Because apparently BMW owners come into this store all the time and buy this stuff. I explained what it was and why it’s delicious.

Anyway, I threw it on my clutch spline and final drive/wheel spline.

Applying Honda Moly 60 to Final Drive

Applying Honda Moly 60 to Wheel Spline

We got the motor back in the frame, (sans oil pan… that would have been difficult (read: impossible)). I threw the new oil pan gasket on there and bolted it all back down. So looking forward to not having a leaky bike.

Installing R65 Oil Pan

And this is how she sits.

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Thursday, December 30th, 2010 BMW Cafe Racer No Comments

Clean Your Boxers

Today I’ve just been cleaning up engine and frame.

I started out by removing the tranny and laying the engine on it’s back to get to the oil pan. I should point out I don’t know if this is allowed….. but I did it. I removed all six thousand oil pan bolts and peeled it off.

You might have noticed the little surprise laying in the pan. Needle bearings. From the rocker arm. That could have probably turned out a little worse….

The pickup strainer had some weird little gasket caught in it. So.. that’s the update on that.

So due to oil leaking from at least 3 places (pushrod tube seals, oil pressure sensor, oil pan, etc….), the motor is basically a giant grease bucket.

A little degreaser (what didn’t make it into my eye) and it’s looking a little better.

I also need to do something about the piston heads. The heads have been dropped off at Day Custom Engine in Richardson, TX for a valve job and honing.

Be careful when removing piston rings. They are VERY sharp.

I also got a chance to do a little work on the frame to prepare it for the powder coater. I don’t know if I ever got a good pic of it, but the rounded back part of the subframe for some reason had been cut and replaced with a pice of rebar. It looked just awful. I don’t know why you would even do that. Anyway… I had a shop in Plano cut it off and weld a new piece of tubular steel in there.

I also took the old grinder to the frame and knocked off all the bits of metal that won’t be used anymore… brackets, and whatnot…

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Tuesday, November 23rd, 2010 BMW Cafe Racer No Comments

Swingarm and Motor Removal

Today I turned my beloved Airhead into a heap of metal, wires, nuts and bolts. Follow me on this heart-wrenching, yet hope-inspiring journey as I venture further into the belly of my tamed beast.

I started out by removing the headlight. Seemed as good a place to start as any. Looking at the photo it kind of brings back memories…..

I managed to rip the wiring harness out (labeling all the important bits), all the while being reminded of the last time I monkeyed with this wiring harness.

Next I knocked the old bars off. I’ll be able to throw these away, as I have a nifty set of clipons. If anybody wants them, email me.

So we pop the boot back by undoing the clamp. These bolts use the other end of your 10mm wrench (the 12-sided part) that you don’t ever use. You’ll probably want to step on the break while you crack these guys loose. ALSO.. BMW recommends you do NOT reuse them. Get new ones.. Capital Cycle has them.

Next I threw a block of wood under the final drive and then set about dropping the rear suspension. It seems like I noticed something important during this step and made a special mental note to say something about this part here.. But I think I’ve thrown the mental note in the can… Sorry.

Now to remove the swingarm. You will need a special 27mm socket from BMW. This socket can be ordered from any BMW Motorcycle dealership and most online BMW parts stores. I’m not certain on the price, but I think it’s in the ballpark of $4,999,999.99……. OR you can just do what I did and use your nifty angle grinder (the one you bought because I pressured you into it in previous posts) to thin the surface around the 27mm socket you’re about to go buy from AutoZone.. You will also more than likely need to flatten the surface of the socket… This will fit into the swingarm tube nicely.

Next you’ll need to arm your ratchet with the longest extension you can find (I’m not sure why I did that) and a 6mm allen wrench. This will be used to remove the swingarm bolt. I know.. you thought you removed it when you removed the two nuts with your newly-fashioned swingarm socket…. but now you have to remove the bolts that the nuts were hanging on to. Don’t question the German engineering. Once these guys come out, you can remove the swingarm.

OH, OH!! I remembered that thing I was going to mention earlier….. I forgot to disconnect the brake linkage from the final drive. I removed everything holding the swingarm and then kept wiggling it trying to remove it, and it wouldn’t come. I eventually realized I’m an idiot and removed the spring-loaded nut holding the linkage connecting the brake lever to the final drive brake actuator. THEN, it will come off.

Next, I had a friend come over, and we pulled the two motor mount bolts and muscled the Boxer Beast over to the workbench where it will be made better, faster, and stronger.

You DID get that angle grinder right?

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Sunday, November 21st, 2010 BMW Cafe Racer No Comments

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