1977 BMW R100RS Rebuilding the Front End

I’ve posted a series of write-ups that cover rebuilding the front end of this bike.  You can find them here:

These write-ups cover disassembly of the handlebars, forks, steering stem, steering damper and fork lock, rebuilding and restoring the wheels, wheel bearings, fork damper rods, fork sliders, steering stem bearings, fork lock, steering damper and installation of a new Toaster Tan top brace and steering stem “acorn” nut.

I also used Speigler braided steel brake hoses, stainless steel caliper brake lines from Rocky Point Cycle.

 

Here is what I started with.

Torn Top Plate of Left Perch

Torn Top Plate of Left Perch

Fork Lock

Fork Lock

Front Wheel Left Side of Hub Showing Corrosion

Front Wheel Left Side of Hub Showing Corrosion

Master Cylinder Grunge and Rust

Master Cylinder Grunge and Rust

Original Caliper is Faded, Axle is Rusty, Fork Lowers Chipped

Original Caliper is Faded, Axle is Rusty, Fork Lowers Chipped

Friction Material Is Separating from Steel Backing Plate

Friction Material Is Separating from Steel Backing Plate

Exterior Fading of Caliper Anodizing

Exterior Fading of Caliper Anodizing

Telefix Fork Brace Needs Refinishing

Telefix Fork Brace Needs Refinishing

Stock Fork Brace-Fender Mount

Stock Fork Brace-Fender Mount

 

And here is what I ended up with.

Fork Lock Installed in Powder Coated Frame

Fork Lock Installed in Powder Coated Frame

Powder Coated Front Wheel with New Wheel Bearings Ready to Roll

Powder Coated Front Wheel with New Wheel Bearings Ready to Roll

Repaired & Painted Control Housings

Repaired & Painted Control Housings

Rebuilt and Refinished Master Cylinder Mounted on Spine Tube

Rebuilt and Refinished Master Cylinder Mounted on Spine Tube

Toaster Tan Top Plate & Steering Stem "Acorn" Nut Mounted

Toaster Tan Top Plate & Steering Stem “Acorn” Nut Mounted

Toaster Tan Top Plate

Toaster Tan Top Plate

Stock Fork-Fender Brace Mounted on Rebuilt Forks

Stock Fork-Fender Brace Mounted on Rebuilt Forks

Speigler Braided Steel & Rocky Point Cycle Stainless Aluminum Caliper Line

Speigler Braided Steel & Rocky Point Cycle Stainless Aluminum Caliper Line

2 thoughts on “1977 BMW R100RS Rebuilding the Front End

  1. In five months exactly you should be well on your way to Harleysville, PA!
    Looks good Brook, keep it up! On my RS rebuild we used cut pieces from a coned veterinary dog collar to protect the powder coated frame under the master cylinder …
    Just sayin …lol

    Andy

    • Hi Andy,

      Yeah, no pressure 🙂 The good news is I received the paint work last week, the replated nikasil cylinders and refurbished connecting rods from Tom Cutter yesterday and the heads are being shipped today. So, almost all the farmed out work is back in my hands.

      Best.
      Brook.

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