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Thread: 1973 R75/5 Rebuild Project Journal

  1. #46
    B Reams brook.reams's Avatar
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    Quote Originally Posted by photorider View Post
    Nice work!
    What did you use on the headers?
    Hi PhotoRider,

    Just click the link I provided and all is revealed :-)

    Best.
    Brook.
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  2. #47
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    Aha!
    Somehow I missed the link before.
    Nice detailed post.
    Those things look fantastic! Let us know how long it lasts.

    Cool project, BTW. Great documentation. Nice to see that bike getting all that love.

  3. #48
    B Reams brook.reams's Avatar
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    1973 R75/5 Rebuild, Repairing Stripped Threads in Handlebar Control Assembly

    As I was putting the handlebar assemblies back together, I discovered a stripped thread in the casting that holds the pinch bolt. I did a HeliCoil repair, which is the first time I have had to repair threads in an expensive part.

    I wrote up a web page on how to repair stripped threads in the assembly.

    Here are a couple the pictures I took along the way.

    Striped Threads & Compression Bolt
    Stripped Thread & Compression Bolt

    Threading Heilcoil Tap
    Running Tap in from Back Side of Assembly

    Threading Insert into Tapped Hole
    Threading the Insert into Tapped Hole From Backside of Assembly

    Here are the finished left and right hand handlebar assemblies with new powder coating and polished levers. *I think they are going to look very nice on the new handlebar.

    Assembled Left Side Clutch Assembly
    Assembled Left Side Clutch Assembly

    Assembled Right Side Throttle Assembly
    Assembled Right Side Throttle Assembly
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  4. #49
    B Reams brook.reams's Avatar
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    1973 R75/5 Refinishing Transmission & Rear Drive

    I posted a short blog about refinishing the transmission, part of the effort this weekend.



    This is not about a rebuild, but a refinish. The blog has links to both the transmission and rear drive web pages with all the refinishing pictures and narrative. I had "fun" getting the kick start and shift lever tapered bolts out, but I polished the bolts and holes and everything went together smoothly. Here are a couple of the pictures you will find.

    Rear Grunge
    Rear Transmission Grunge

    Top Side Grunge
    Top Transmission Grunge

    Front Gunge
    Front Transmission Grunge

    Polished Parts
    Polished Pieces

    Refinished Top
    Refinished Transmission Top

    Refinished Left Side
    Refinished Transmission Left Side

    Rear Drive Before Cleaning
    Rear Drive Before Cleaning

    Brake Shoe Orientation
    Inside Rear Drive Showing Brake Shoe Orientation

    Refinished Rear Drive
    Inside Rear Drive Refinished with Polished Parts

    Refinished Rear Drive
    Outside Rear Drive Refinished
    Last edited by brook.reams; 04-12-2013 at 10:33 PM.
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  5. #50
    B Reams brook.reams's Avatar
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    1973 R75/5 Refinishing Boge Rear Shocks

    I removed and inspected the Boge rear shocks to see if they could be used. I really wanted to retain the stock chrome shock covers if possible. I decided they are still serviceable, so I refinished them including powder coating the springs and removing the deep scratches in the shock covers. I wrote up a web page on this and here is the direct link to it.



    Below are a couple of the pictures included in the web page write up.

    Hose Clamp Spring Compressor
    Hose Clamp Spring Compressor

    Shackle and Spring Removed
    Shackle and Spring Removed

    Polished & Powder Coated Parts
    Polished & Powder Coated Parts

    Refinished Shock
    Refinished Shock
    Last edited by brook.reams; 04-12-2013 at 10:34 PM.
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  6. #51
    B Reams brook.reams's Avatar
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    1973 R75/5 Swing Arm, Bearing Replacement & Powder Coat

    I posted another chapter on this project about replacing the swing arm bearings and powder coating the swing arm. This blog post has a link to the web page I wrote about this.



    I hope this is helpful to folks. Here are few sample pictures from the web page to wet your appetite.

    Cycle Works Swing Arm Bearing Puller Kit
    Cycle Works Swing Arm Bearing Puller Kit

    Removing the Spacer
    Removing the Spacer

    Puller Positioned to Remove the Dust Seal
    Puller Positioned to Remove the Dust Seal

    Progresso Soup Can "Sock" Over the Universal Joint
    Progresso Soup Can "Sock" Over the Universal Joint

    Powder Coated Swing Arm
    Powder Coated Swing Arm

    Swing Arm Bearing Parts-Top to Bottom, Inside to Outside
    Swing Arm Bearing Parts-Top to Bottom, Inside to Outside, Left is Drive Shaft Side, Right is Shock Side

    Shock Side, Bearing Race and Grease Cap Installed
    Shock Side Showing Bearing Race and Grease Cover Installed

    Dust Seal with Sleeve Installed
    Dust Seal with Sleeve Installed
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  7. #52
    B Reams brook.reams's Avatar
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    1973 R75/5 Replacing Steering Head Bearings

    Folks,

    I posted a report on this part of the project:
    http://brook.reams.me/about/bmw-moto...head-bearings/

    that contains a link to a web page I wrote up about what I did:
    http://brook.reams.me/about/bmw-moto...head-bearings/

    This is a milestone on the project as I am now reassembling parts in the frame instead of disassembling them.

    I hope this material is helpful to others. Here are a couple of the many pictures I put in the web page.

    Fork tubes removed
    Steering Head After Forks Removed

    Steering Stem
    Steering Stem Showing Top Bearing

    BMW Steering Head Race puller
    BMW Steering Head Race puller

    Old Race-Vertical Bands Indicate Brinelling
    Top Race with Vertical Bands Indicating Brinelling

    Bottom Bearing Slipped On and Seated on the Steering Stem
    Bottom Bearing Slipped On and Seated on the Steering Stem

    Top & Bottom Bearings Packed with Grease
    Top & Bottom Bearings Packed with Grease

    New Chrome Top Dust Cap Really Shines
    New Chrome Top Dust Cap Really Shines
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  8. #53
    B Reams brook.reams's Avatar
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    1973 R75/5 Rebuild, Measuring Cylinders & Pistons, Installing New Rings

    I documented this work here.
    1973 BMW R75/5 Rebuild: Measuring Cylinders, Pistons and Installing New Rings

    It contains a link to the web page I wrote up with the details of what I did.

    I hope this is useful to others who are considering doing this kind of work.

    Here is a sample of the pictures I took along the way.

    Zeroing Micrometer with 3 inch Reference
    Zeroing Micrometer

    Bore Guage
    Bore Gauge with Dial Indicator

    Setting Bore Gauge
    Setting Bore Gauge to Known Length

    Bore Diameter
    Measuring Bore Diameter

    Measuring Piston Diameter on Thrust Side of Skirt
    Measuring Piston Diameter on Wide Side

    Inserting Hone in Cylinder
    Inserting Hone in the Cylinder

    New Rings
    New Rings, One Over Size

    Positioning Ring for Grinding Gap
    Positioning Ring In Ring Grinder

    Measuring Ring End Gap
    Measuring End Gap - Perfect
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  9. #54
    B Reams brook.reams's Avatar
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    R75/5 Rebuild: Clutch Removal and Inspection

    It has been awhile since I posted on this project. My wife and I spent six weeks in Europe celebrating our 35th anniversary by participating in some "applied motorcycling" taking two motorcycle tours and doing some sight seeing.

    Here is a link to a recent progress report on the project:
    http://brook.reams.me/2013/08/08/197...ress-report-2/

    This is a link to today's posting about removal and inspection of the clutch;
    http://brook.reams.me/2013/08/13/197...nd-inspection/

    And for those interested in riding in eastern Europe in what was once Yugoslavia as well as Bulgaria and Albania, here is my trip report. I'll post one on the tour of the Pyrenees pretty soon.
    http://brook.reams.me/2013/07/12/a-m...n-the-balkans/

    And, a tip of the hat to Tom Cutter and Bob Fleischer (aka, Snowbum) for sharing their considerable knowledge. It is much appreciated. And of course any mistakes made in my work are mine alone and do not reflect on these guys. ;-)

    Here are some of the pictures from my write up.

    Bar Preventing Rotation When Removing Clutch Bolts
    Bar Preventing Rotation When Removing Clutch Bolts

    Backing Off Clutch Pressure 1/2 Turn Per Bolt at a Time
    Backing Off Clutch Pressure 1/2 Turn Per Bolt at a Time

    Clutch Parts Order: Bottom Clutch Pressure Ring, Top Clutch Diaphragm Spring
    Clutch Parts Order: Bottom Clutch Pressure Ring, Top Clutch Diaphragm Spring

    Diaphragm Spring Finger-Wear on Edges
    Diaphragm Spring Finger-Wear on Edges

    Clutch Pressure Plate Facing Engine Showing Grooves from Diaphragm Spring
    Clutch Pressure Plate Facing Engine Showing Grooves from Diaphragm Spring
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  10. #55
    rsbeemer 22600's Avatar
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    I got in here late

    But, thank you Brook for all the nice pics and your journal. You do nice work and contributions like this help us all.

    DW
    1978 R100rs MOA#22600 125cc Kymco
    The pessimist complains about the wind; the optimist expects it to change; the realist adjusts the sails.

  11. #56
    B Reams brook.reams's Avatar
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    Quote Originally Posted by 22600 View Post
    But, thank you Brook for all the nice pics and your journal. You do nice work and contributions like this help us all.

    DW
    Thanks for the kind words DW. For some reason, documenting this type of work is enjoyable to me, and of course doing the work is engaging and challenging, so I have a good time.

    PS: I like that RS in your photo. I lust for one to rebuild and it is on my list for "next projects".
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  12. #57
    B Reams brook.reams's Avatar
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    R75/5 Rebuild: Remove/Replace Flywheel, Replace Oil Pump Cover & Cover O-ring

    I posted a new page on this project about removing the flywheel, replacing the rear main seal, oil pump cover and cover o-ring and installing the flywheel. This also covers a repair to a leak I found in one of the crankshaft flywheel bolt holes.

    http://brook.reams.me/2013/08/14/197...er-and-o-ring/

    The work I did was guided by a lot of advice and web content shared by others who have gone before me. I?d like to acknowledge folks Tom Cutter who runs Rubber Chicken Racing Garage and Bob (Snowbum) Fleischer who has a great technical library on all things BMW motorcycles, answered questions I posted on the Micapeak forum and in personal Email and phone conversations. I also used web materials posted on Duane Ausherman?s site.

    Any errors in procedure are entirely my own and in no way reflect on the knowledge of the people above.

    Here are a couple pictures from the many posted in the write-up.

    10mm Long Bolt in Alternator to Block Crackshaft
    10mm Long Bolt in Alternator to Block Crackshaft

    Flywheel Bolts out And Oil Leaking<
    Flywheel Bolts Out And Oil Leaking From Crankshaft Hole

    Removing Oil Pump Cover with Impact Driver
    Removing Oil Pump Cover with Impact Driver

    Tightening Bolt to Pull Rear Main Seal
    Tightening Bolt to Pull Rear Main Seal

    Heated to 220 F
    Heating Flywheel Bolt Circle to 220 F Prior To Installation
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  13. #58
    advrider.com
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    Quote Originally Posted by brook.reams View Post

    Clutch Pressure Plate Facing Engine Showing Grooves from Diaphragm Spring
    Geez, that's wild! That must have been one gritty feeling clutch.

    Quote Originally Posted by brook.reams View Post

    Removing Oil Pump Cover with Impact Driver
    How in the heck can you get a swing in that small space? It's impossible to use a handheld impact on my /6s.

  14. #59
    B Reams brook.reams's Avatar
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    Quote Originally Posted by crazydrummerdude View Post
    Geez, that's wild! That must have been one gritty feeling clutch.



    How in the heck can you get a swing in that small space? It's impossible to use a handheld impact on my /6s.
    Hi CrazyDrummerDude,

    Thanks for visiting this thread.

    [gritty clutch] The bike had not been ridden for 6 years before I started rebuilding it. That said, it is my wife's bike so I haven't any sense of how the clutch was working, but it was working when I put it up on blocks 6 years ago. Based on the measurements, it didn't have much life left.

    [impact driver comment] Indeed, this is not as easy if the engine is in the frame. But mine's out of the frame. However, with the transmission, rear frame and swing arm removed, you have room to use the mallet. It doesn't take a big swing to get the torque onto the screw head.
    Last edited by brook.reams; 08-26-2013 at 03:44 PM.
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  15. #60
    advrider.com
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    Quote Originally Posted by brook.reams View Post
    [impact driver comment] Indeed, this is not as easy if the engine is in the frame. But mine's out of the frame.
    I picked the wrong day to stop sniffing glue! Yeah, I totally see that today and yet didn't notice it yesterday.

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