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Thread: 1973 R75/5 Rebuild Project Journal

  1. #91
    B Reams brook.reams's Avatar
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    1973 R75/5 Rebuild, Install Front Brakes

    Folks,

    More progress as I now have the new front brakes, brake cable & handlebars installed. You can read about how I did this work here.
    • 34 BMW R75/5 Install Front Brakes

    Thanks to Bob Fleischer, again, for tips and tricks and to Duane Ausherman and Scott Lydiard for their publications.

    I'm working on installing all the electrics next.

    Here are a couple pictures from the write-up on this work.

    Front Brake Carrier (Front to the Right)
    Front Brake Carrier (Front to the Right)

    Front Brake Assembly
    Front Brake Assembly

    Rear Brake Cam Shaft Lever and Adjustment Cam
    Front Brake Arm Cam with Lever and Adjustment Cam

    Front Spring Installed and Shoes on Pivot Pins
    Front Spring Installed and Shoes on Pivot Pins

    Scott  Lydiard's Brake Lever Alignment Template
    Scott Lydiard's Brake Lever Alignment Template

    Using Scott Lydiard's Front Brake Lever Alignment Template
    Using Scott Lydiard's Front Brake Lever Alignment Template

    Front Axle with Spacer Sleeve
    Front Axle with Spacer Sleeve

    Front Brake Hub, Brake Arm & Wheel Installed
    Front Brake Hub, Brake Arm & Wheel Installed

    Right Control Perch Assemble
    Right Control Perch Assemble

    Brake Cable Assembly at Right Control Perch
    Brake Cable Assembly at Right Control Perch

    Inserting Ferrule in Rear Brake Lever to Capture Outer Sleeve of the Cable
    Inserting Ferrule in Rear Brake Lever to Capture Outer Sleeve of the Cable

    Adjusting Lower Cable
    Adjusting Lower Cable

    Adjusting Brake Cam for 4 mm Slack in Front Brake Lever
    Adjusting Brake Cam for 4 mm Slack in Front Brake Lever

    Brakes Are Solid at 1/2 Distance to Handlebar
    Brakes Are Solid at 1/2 Distance to Handlebar

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

  2. #92
    B Reams brook.reams's Avatar
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    1973 R75/5 Rebuild, Install Electrical System

    Folks,

    I finished installing the electrical system and performed a smoke test. NO SMOKE

    Here's the link to the write-up on how I did this part of the project.


    It's starting to look like a motorcycle once again. Now I have to decide if I start work on restoring the paint or finish installing the engine (heads, cylinders, etc.)

    In the meantime, here are a few of the many pictures included in the write-up. I took a lot of pictures to help show how the various branches of the wiring harness are routed.

    Broken Wiring Harness Sheath
    Broken Wiring Harness Sheath

    Corroded Lug on Starter Relay Wire to (+) Battery Terminal
    Corroded Lug on Starter Relay Wire to (+) Battery Terminal

    Starter Relay Wiring Notes
    Starter Relay Wiring Notes

    Engine Wires Attached to Starter Relay
    Engine Wires Attached to Starter Relay

    Horn Assembly
    Horn Assembly

    Attaching Headlight Shell Gaskets
    Attaching Headlight Shell Gaskets

    Threading Main Wiring Harness From Headlight Along Frame Backbone
    Threading Main Wiring Harness From Headlight Along Frame Backbone

    Starting to Pull Rear Frame Wiring Branch Through Rear Frame Tube
    Starting to Pull Rear Frame Wiring Branch Through Rear Frame Tube

    Routing Neutral Switch & Oil Pressure (Through Hole in Frame Gusset) and Rear Brake Light Wires (Under Battery Box)
    Routing Rear Brake Light Wires (Under Battery Box)

    Transmission Neutral Switch Wire
    Transmission Neutral Switch Wire Routing Underneath the Frame

    Connect Battery (+) Cable to Starter
    Connect Battery (+) Cable to Starter Motor Solenoid

    Starter Cable Routing Between Coils
    Starter Solenoid Cable Routing in Rubber Wire *Loom & Between Coils

    Smoke Test Success - It's ALIVE!!!
    Smoke Test Success - It's ALIVE!!!
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  3. #93
    B Reams brook.reams's Avatar
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    1973 R75/5 Rebuild, Install Engine Top End

    Folks,

    Well, this work is done and the bike is really looking like an airhead with it's ears in the wind :-)

    You can read about the work I did here:

    • 11 BMW R75/5 Install Engine Top End


    Thanks to Oak Okleshen, Bob Fleischer, Tom Cutter, Duane Auscherman and Anton Lagiardier for publishing materials and answering questions. Any mistakes I made are mine and do not reflect on their publications or advice.

    Next up is exhaust, carburetors and seat.

    Here a samples of the pictures you'll find in the write-up.

    Progress So Far
    Progress So Far-Ready To Install Engine Top End

    Left Side Exhaust Cam and Follower
    Exhaust Cam Showing Off-center Cam Follower

    Too Much Expansion Gets You a Broken Oil Control Ring :-(
    Too Much Expansion Gets You a Broken Oil Control Ring :-([/caption]

    All Three Rings Installed with Top Of Ring Facing Top of Piston
    All Three Rings Installed with Top Of Ring Facing Top of Piston

    Correct Left Side Piston Orientation with "Vorn" Pointing to Front
    Correct Left Side Piston Orientation with "Vorn" Pointing to Front

    Inserting Piston in Cylinder with Ring Compressor
    Inserting Piston in Cylinder with Ring Compressor

    Hylomar on Engine Case
    Hylomar on Engine Case

    Frozen Wrist Pin and C-rings
    Frozen Wrist Pin and C-rings

    Push Rod Tube Drawn Tight to Engine Casing
    Push Rod Tube Rubber Drawn Tight to Engine Casing

    Proper Orientation of Rocker Block (Slot Facing Outside of Head) and Nut Boss on Face of Block
    Proper Orientation of Rocker Block (Slot Facing Outside of Head) and Nut Boss on Face of Block

    Measuring Distance Between Rocker Blocks
    Measuring Distance Between Rocker Blocks

    View From the Saddle
    View From the Saddle
    Last edited by brook.reams; 12-23-2013 at 08:05 PM.
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  4. #94
    B Reams brook.reams's Avatar
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    1973 R75/5 Rebuild, Install Exhaust and Sito Mufflers

    Folks,

    I installed new Sito mufflers on the cleaned up header pipes over the Christmas break. Here is the write-up.

    • 18 BMW R75/5 Install Exhaust System

    The mufflers look to be nice quality and were easy to install. Everything lined up with no hassles. I'll see how well they wear as time goes by.

    Next up, carburetor and cable installation.

    Here are a couple of the pictures from the write-up.

    Sito Muffler Parts
    Sito Muffler Parts

    Exhaust Header Pipes
    Exhaust Header Pipes

    Orientation of Exhaust Header Seal Rings
    Orientation of Exhaust Header Seal Rings

    Mounting Muffler Bracket to Bottom of Muffler
    Mounting Muffler Bracket to Bottom of Muffler

    Tightening Exhaust Header Nut
    Tightening Exhaust Header Nut

    Sito Exhaust Installed
    Sito Exhaust Installed

    Sito Exhaust Installed
    Sito Exhaust Installed

    Sito Exhaust Installed
    Sito Exhaust Installed

    Best.
    Brook Reams
    Last edited by brook.reams; 12-30-2013 at 09:06 PM.
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  5. #95
    B Reams brook.reams's Avatar
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    1973 R75/5 Rebuild, Painting Engine Badges

    Folks,

    A short write-up on how I refreshed the engine badges.

    • 51 BMW R75/5 Paint Engine Badge

    I hope this is helpful. It took me some time to polish up the lettering as there were faded areas on the letters, but it looks pretty nice now.

    Quick Bench Top Paint Booth
    Quick Bench Top Paint Booth

    Masked Starter Motor Cover
    Masked Starter Motor Cover

    Badge Painted with Black Brake Caliper Paint Badge Painted with Black Brake Caliper Paint[/caption]

    Baking at 200 F for 20 Minutes
    Baking at 200 F for 20 Minutes


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

  6. #96
    Registered User lmo1131's Avatar
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    Outstanding documentation Brook, it almost makes me want to tear mine down again just to freshen things up a bit ... almost. And I'm glad to see your smoke test was successful, I was going to offer you some of the extra smoke that I had left over from mine... ..

    What adhesive did you end up using for securing the engine plates?
    "It is what you discover, after you know it all, that counts." _ John Wooden

    Lew Morris
    1973 R75/5 - original owner

  7. #97
    B Reams brook.reams's Avatar
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    Quote Originally Posted by lmo1131 View Post
    Outstanding documentation Brook, it almost makes me want to tear mine down again just to freshen things up a bit ... almost. And I'm glad to see your smoke test was successful, I was going to offer you some of the extra smoke that I had left over from mine... ..

    What adhesive did you end up using for securing the engine plates?
    Hi Lew,

    Thanks for the kind offer of the extra smoke for testing. With the recent legalization of MJ for personal use in Colorado, there is now a ready supply of same in these parts :-)

    I did not remove the badges, I painted them in place, so I can't advise on adhesive if you want to reattach. Somewhere in the back of my brain, "Gorilla Snot" has been mentioned for this.
    http://boxerworks.com/forum/viewtopic.php?f=1&t=3561

    If you do dive in for a "Freshen Up", I'm sure you will have a great experience.

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

  8. #98
    B Reams brook.reams's Avatar
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    1973 R75/5 Rebuild, Installing Carburetors and Cables

    Folks,

    Well, one step closer to a "First Engine Start" on this project. Just about everything needed is done before trying to start the engine after seven years of hibernation.

    I wrote-up putting the choke lever assembly back together, and installing the carburetor's and cables on the bike.

    • 13 BMW R75/5 Install Carburetors and Cables

    But, work intervenes so back to earning a wage instead of the joy of bringing the bike back to life.

    Here a couple pictures from the write-up.

    Choke Assembly Parts
    Choke Lever Parts

    Choke Body and Cables Installed on Left Air Box Cover
    Choke Body and Choke Cables Installed on Left Air Box Cover

    Back Side of Carburetor Showing Coke Cable Nipple Installation
    Back Side of Carburetor Showing Choke Cable Adjuster Installation

    Alignment Marks on Twist Grip & Throttle Cam
    Alignment Marks on Twist Grip & Throttle Cam

    Carburetor Vertical Alignment
    Carburetor Vertical Alignment

    From the Saddle View of Carburetor with Cables Installed
    From the Saddle View of Carburetor with Cables Installed
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  9. #99
    Registered User JGREGOR1.JG's Avatar
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    Everything looks so spectacular. Just great work sir.
    Jim Gregory
    92 R100RS
    05 Sportster Roadster

  10. #100
    B Reams brook.reams's Avatar
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    1973 R75/5 Rebuild, Install New Plug Wires

    Folks,

    One other small bit of work completed on New Years day.

    • 12 BMW R75/5 Install Spark Plug Wires

    At this point, I'm preparing for first engine start by going over what I've done and doing simple tests to try and find any mistakes and correct them.

    Perhaps I'll be able to make a short video of the blessed event so you can join me in the celebration of bringing yet another airhead engine back to life :-)

    Here is what she looks like from the saddle at this point.

    Spark Plugs and Cables Installed
    Spark Plugs and Cables Installed
    Last edited by brook.reams; 01-02-2014 at 09:59 PM.
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  11. #101
    Registered User R100RTurbo's Avatar
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    Back to Work

    [QUOTE=brook.reams;915380]Folks,

    Well, one step closer to a "First Engine Start" on this project. Just about everything needed is done before trying to start the engine after seven years of hibernation.

    I wrote-up putting the choke lever assembly back together, and installing the carburetor's and cables on the bike.

    • 13 BMW R75/5 Install Carburetors and Cables

    But, work intervenes so back to earning a wage instead of the joy of bringing the bike back to life.




    Thank you for your mention of blending work and shop time - I've been rather jealous of your project and seeming unlimited time to perform your magic when I have to wait for weekends and then early morning sessions at that - where a few hours spent in the shop won't upset the family balance.

  12. #102
    B Reams brook.reams's Avatar
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    [QUOTE=R100RTurbo;915453]
    Quote Originally Posted by brook.reams View Post
    Folks,

    Thank you for your mention of blending work and shop time - I've been rather jealous of your project and seeming unlimited time to perform your magic when I have to wait for weekends and then early morning sessions at that - where a few hours spent in the shop won't upset the family balance.
    R100RTurbo,

    Yes, I had to learn to control my antsy urges to go out into the shop when I know the wife and "chore boy" duties need my attention.
    ---------------------------------
    Brook Reams - Arvada, CO
    Various Two-wheeled Vices, All BMW
    2004 R1150-RS || 2002 F650-GS || 1975 R75/6 || 1973 R75/5

  13. #103
    Smoooooth at 430 gch71's Avatar
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    Awesome project!!!

    Thats really comming along nicely, I really enjoy going through the thread and following along. I have one question for you and others out there concering the Off-center Cam Follower on the exhaust (the one in the picture). Is that normal? I have noticed that the ones on my airhead are the same or close to it?
    thanks and keep up the great work!!
    Last edited by gch71; 01-03-2014 at 09:42 PM. Reason: grammer mmmmmmm
    Glenn
    ...driving to work on my airhead
    '74 R60/6, '75 R60/6(boxes)

  14. #104
    B Reams brook.reams's Avatar
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    Quote Originally Posted by gch71 View Post
    Thats really comming along nicely, I really enjoy going through the thread and following along. I have one question for you and others out there concering the Off-center Cam Follower on the exhaust (the one in the picture). Is that normal? I have noticed that the ones on my airhead are the same or close to it?
    thanks and keep up the great work!!
    Hi Glenn,

    Thanks for the kind words, I appreciate them.

    Yes, the off-center cam follower is intentional. In the write-up (follow the link: 11 BMW R75/5 Install Engine Top End) I explain why this is done and what the value is. That said, I wasn't prepared for that when I was looking closely inside the engine and was scratching my head as to how on earth anything I did could have possibly caused the cam shaft to move. Of course, I hadn't done anything, the off-center orientation is normal.

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

  15. #105
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    1973 R75/5 Rebuild, "Grover's" First Engine Start

    Folks,

    As promised, here is the write-up on the attempted first engine start on this project.

    • 00 BMW R75/5 Grover?s First Engine Start

    At the end of the write-up is a video of Grover being slapped in the delivery room to try and get him to cry ... I'm not going to tell you how that went, you can watch the video and see for yourself.

    Here are a couple photos from the write-up.

    Grover's Delivery Room - The Workshop
    Grover's Delivery Room - The Workshop

    Off the Lift on One Leg
    Off the Lift on One Leg

    Center Stand Parts
    Center Stand Parts

    Installing Centerstand Spring on Engine Mount
    Installing Centerstand Spring on Engine Mount

    Adjusted Side Stand to Prevent Springing Back
    Adjusted Side Stand to Prevent Springing Back

    Grover Standing on His Own Two Feet :-)
    Grover Standing on His Own Two Feet :-)

    Using Ohm Meter to Static Time - Closed =  0 Ohms
    Using Ohm Meter to Static Time - Closed = 0 Ohms

    Checking Carburetor Fuel Level in Float Bowls
    Checking Carburetor Fuel Level in Float Bowls

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

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