34 BMW 1983 R100RS Remove Brake System

This year and model has dual front disk brakes and a single rear disk brake. BMW switched to Brembo from ATE for their disk brakes in the 1981 model year, starting in September 1980, so this bike has Brembo brakes. This is what the bike looks like when I started removing the brake system.

Ready to Remove Brakes

Ready to Remove Brakes

This document covers removing the front and rear brakes (calipers, steel and rubber brake lines, master cylinders and brake fluid reservoirs) but not removing the disks and the front brake master cylinder which is integrated with the right side handlebar controls. I remove the disks when I remove the wheels and tires, and the right side handlebar control when I remove the steering components.

Remove Front Brake Assembly

This short video shows how the components of the front brake assembly are mounted.

VIDEO: 1983 BMW R100RS Front Brake Assembly

Drain Front Master Cylinder

The Brembo dual front brake system master cylinder and brake fluid reservoir are integrated into the right handlebar perch along with the throttle.

Front Brake Fluid Reservoir & Master Cylinder Mounts to Right Handlebar Perch

Front Brake Fluid Reservoir & Master Cylinder Mounts to Right Handlebar Perch

I start by opening the fluid reservoir on the handlebar and and removing the internal rubber diaphragm and the black plastic gasket on top of the diaphragm.

Remove Front Brake Fluid Reservoir Cover

Remove Front Brake Fluid Reservoir Cover

Front Brake Fluid Reservoir Hardware Detail

Front Brake Fluid Reservoir Hardware Detail

Front Brake Fluid Reservoir Cover & Diaphragm Detail

Front Brake Fluid Reservoir Cover & Diaphragm Detail

Front Brake Fluid Cover Hardware Detail

Front Brake Fluid Cover Hardware Detail

Front Brake Reservoir Internals Detail: (Top) Diaphragm, (Middle) Plastic Gasket, (Bottom) Cover

Front Brake Reservoir Internals Detail: (Top) Diaphragm, (Middle) Plastic Gasket, (Bottom) Cover

The fluid is the color of strong tea, which is not a good sign of frequent brake fluid changes. I remove the fluid with a syringe.

Front Brake Fluid-Ugly!!!!

Front Brake Fluid-Ugly!!!!

Remove Brake Fluid From Front Reservoir With Syringe

Remove Brake Fluid From Front Reservoir With Syringe

NOTE:
I took the lines apart starting at the master cylinder. But, I think it’s better if you start at the caliper so the brake fluid continues to drain out from the bottom and you work your way up to the top master cylinder. Your choice 🙂

Remove Master Cylinder Brake Line

Next, I remove the banjo bolt that secures the top of the rubber line to the master cylinder.

Remove Front Master Cylinder Brake Line

Remove Front Master Cylinder Brake Line

Front Master Cylinder Brake Line Detail

Master Cylinder Banjo Bolt Detail

There are two copper washers that go on either face of the banjo bolt, or said differently, one goes against the master cylinder face and the other against the rubber brake hose face.

Master Cylinder Banjo Bolt Detail

Master Cylinder Banjo Bolt Detail

At the front of the brake line splitter-manifold is the rubber line from the master cylinder. I remove the fitting from the splitter-manifold.

Remove Master Cylinder Brake Line From Splitter Manifold

Remove Master Cylinder Brake Line From Splitter-Manifold

Master Cylinder Line To Splitter Manifold Detail

Master Cylinder Line To Splitter-Manifold Detail

Remove Steel Brake Lines From Splitter-Manifold

The splitter-manifold has two steel brake lines that feed the twin front disk brakes mounted on each side of the splitter-manifold. I remove these.

Front Brake Caliper Line From Splitter-Manifold

Front Brake Caliper Line From Splitter-Manifold

Remove Front Brake Line From Splitter-Manifold

Remove Front Brake Line From Splitter-Manifold

Front Steel Brake Line at Splitter-Manifold Detail

Front Steel Brake Line at Splitter-Manifold Detail

Then I unscrew the union between the rubber brake line and the splitter-manifold steel line to remove the steel line. The union has a rubber grommet in the hole. This grommet mounts in a slot in the center middle fairing panel to secure the brake line.

Front Brake Line Union in Center Middle Fairing Panel

Front Brake Line Union in Center Middle Fairing Panel

Separating Brake Manifold Steel Line From Rubber Line

Separating Brake Splitter-Manifold Steel Line From Lower Rubber Line

Front Brake Fairing Bracket Grommet

Front Brake Fairing Bracket Grommet

Front Steel Brake Line To Splitter-Manifold

Front Steel Brake Line To Splitter-Manifold

Remove Front Brake Line Splitter-Manifold

The front brake line splitter-manifold has the ignition control unit bolted to the top. I remove it. The back of the ignition control unit has a shiny metal pad which attaches to the top of the splitter-manifold. The splitter-manifold acts as a heat sink and requires heat sink paste to be applied to the shiny metal pad periodically for good heat transfer from the ignition control unit.

Remove Ignition Control Module From Top of Front Brake Line Splitter-Manifold

Remove Ignition Control Module From Top of Front Brake Line Splitter-Manifold

Ignition Control Model Hardware Detail

Ignition Control Model Hardware Detail

Ignition Control Model Hardware Detail

Ignition Control Model Hardware Detail

Back of Ignition Control Module Showing Shiny Area for Heat Sink Paste

Back of Ignition Control Module Showing Shiny Area for Heat Sink Paste

The ignition control unit is attached to the frame spine using a steel clamp that I remove.

Front Brake Switch Detail Showing Steel Strap That Secures Ignition Control Unit to Spine Tube

Front Brake Switch Detail Showing Steel Strap That Secures Ignition Control Unit to Spine Tube

Removing Front Brake Line Manifold Steel Strap

Removing Front Brake Line Splitter-Manifold Steel Strap

Front Brake Line Splitter-Manifold Detail

Front Brake Line Splitter-Manifold Detail

Front Brake Line Manifold Detail

Front Brake Line Manifold Detail

Remove Front Caliper Steel Brake Line & Bleed Screw

Next, I disconnect the caliper steel brake line from the lower rubber line at the bracket mounted to the rear fork brace bolt. This connection is similar to the upper union and has a rubber grommet that fits inside the hole in the bracket.

Front Brake Caliper Steel Line-to-Rubber Hose Union Detail

Front Brake Caliper Steel Line-to-Rubber Hose Union Detail

Separating Front Caliper Steel Brake Line From Rubber Line at Bracket

Separating Front Caliper Steel Brake Line From Rubber Line at Bracket

Front Caliper Brake Line Detail

Front Caliper Brake Rubber Line Detail

The steel and rubber line fittings fit inside a rubber grommet in the hole of the brake line bracket.

Front Caliper Brake Line & Bracket Detail

Front Caliper Steel Brake Line & Bracket Detail

Then I remove the bleed screw and steel brake line on both front calipers.

Front Brake Caliper Line & Drain Screw Detail

Front Brake Caliper Line & Drain Screw Detail

Remove Front Caliper Bleed Screw

Remove Front Caliper Bleed Screw

Front Caliper Bleed Screw Detail

Front Caliper Bleed Screw Detail

Front Caliper Steel Line Detail-Note Corrosion The End Of The Fitting

Front Caliper Steel Line Detail-Note Corrosion The End Of The Fitting

Brembo Front Caliper Steel Brake Line

Brembo Front Caliper Steel Brake Line

Brembo Front Caliper Rubber Hose and Steel Brake Line

Brembo Front Caliper Rubber Hose and Steel Brake Line

Remove Front Caliper and Brake Line Bracket

The front caliper is secured to the front fork slider with two Allan head bolts. The other two bolts in the caliper are used to assemble the two halves.

Front Caliper Mounting Bolts

Remove Brembo Front Brake Caliper

Brembo Front Brake Caliper Hardware Detail

Once the two bolts are removed, the caliper slides off the disk.

Removing Brembo Front Brake Caliper

Brembo Front Disk Brake Detail

Front Disk Brake Caliper Mounting Tabs on Front Fork Slider

Front Disk Brake Caliper Mounting Tabs on Front Fork Slider

The disk pads look fairly new.

Brembo Front Disk Brake Pads Are Barely Worn

Brembo Front Disk Brake Pads Are Barely Worn

This is the Brembo part number stamped into the back of the caliper.

Brembo Front Caliper Part Number on Back of Caliper

Brembo Front Caliper Part Number on Back of Caliper

The front caliper brake line union bracket is secured by the rear fork brace Allan bolt underneath the nut. I remove the rear lock nut and remove the bracket which is very rusty.

Front Caliper Brake Line Bracket Mounts to Rear Fork Brace Bolt

Front Caliper Brake Line Bracket Mounts to Rear Fork Brace Bolt

Remove Front Caliper Brake Line Bracket

Remove Front Caliper Brake Line Bracket

Front Brake Caliper Line Bracket Detail-Very Rusty

Front Brake Caliper Line Bracket Detail-Very Rusty

Remove Rear Brake System

The Brembo single disk rear brake system has its own master cylinder mounted on the inside of the right hand muffler bracket next to the swing arm. The fluid reservoir is attached to the frame battery box bracket with a steel strap. Here is a short video showing how the rear master cylinder and mounting bracket, and the rear brake pedal are mounted.

VIDEO: 1983 BMW R100RS Master Cylinder Mounting

NOTE:
Due to battery acid leaks, there was a lot of rust on the master cylinder bracket and the special pin that secures the top of the brake pedal to the master cylinder plunger linkage. I could not get the special pin to come out, so I had to remove the master cylinder on the bracket with the rear brake pedal attached which is harder to do, but can be done.

The rear caliper is on the left side of the bike with a steel brake line from the outlet of the master cylinder connecting to a rubber brake line that attaches to the rear brake caliper. The caliper mounts to a plate that attaches to the rear axle and is secured with a brake stay, or torque rod, to a bracket on the bottom of the swing arm. Here is a short video showing how these are mounted.

VIDEO: 1983 BMW R100RS Rear Caliper Mounting

Detach Rear Master Cylinder Fluid Reservoir and Drain

The rear master cylinder fluid reservoir is secured using a metal strap that attaches tothe top, right rear battery box rubber isolation damper. This damper has one longer thread than the other four to secure the rear fluid reservoir mounting strap.

Rear Brake Fluid Reservoir Mounts to Top Right Battery Box Vibration Damper Stud

Rear Brake Fluid Reservoir Mounts to Top Right Battery Box Vibration Damper Stud

After I remove it, I open the top and pour the fluid out of the reservoir.

Remove Rear Brake Pedal Assembly

The rear brake pedal is attached to the frame with a long bolt through a boss welded to the frame. There is a lock nut and washer on the back.

Rear Brake Pedal Pivot Bolt

Rear Brake Pedal Pivot Bolt

Rear Brake Pedal Pivot Bolt Detail

Rear Brake Pedal Pivot Bolt Detail

Remove Rear Brake Pedal

Remove Rear Brake Pedal

The bolt and other hardware on this bike is not stock. Someone tried to fix the wobble in the brake pedal using a longer shoulder bolt, a metal cap and some aluminum can for shim. Brake pedal wobble is caused by lack of lubrication of the bolt that fits inside a bushing. The bushing and bolt wear and loosen up causing more wear. I will replace the bushing and get the proper hardware.

Not Stock Brake Pedal Pivot Bolt Hardware Detail

Not Stock Brake Pedal Pivot Bolt Hardware Detail

Not Stock Brake Pedal Pivot Bolt Hardware Detail

Not Stock Brake Pedal Pivot Bolt Hardware Detail

The brake pedal is secured to the master cylinder plunger linkage with a special pin. In theory, you push down on the retaining clip that fits over the bushing of the master cylinder linkage, rotate it 90 degrees and then pull the pin out. But mine is badly rusted so I will have to remove the master cylinder and bracket with the rear brake pedal attached.

Rear Brake Pedal Linkage With Special Pin-Rusted Tight

Rear Brake Pedal Linkage With Special Pin-Rusted Tight

Remove Rear Master Cylinder & Bracket

At the rear of the master cylinder there is a spring that attaches to a hole in the rear muffler bracket. This is the brake pedal return spring that I remove.

Rear Brake Pedal Return Spring Fits In Hole in The Muffler Bracket

Rear Brake Pedal Return Spring Fits In Hole in The Muffler Bracket

Remove Rear Brake Pedal Return Spring

Remove Rear Brake Pedal Return Spring

The steel brake line from the master cylinder to the rear brake caliper attaches to the rear of the master cylinder and I remove it.

Remove Rear Master Cylinder Steel Brake Line

Remove Rear Master Cylinder Steel Brake Line

The master cylinder attaches to a bracket. The bracket is secured at the rear by the rear muffler bracket bolts. To get the bracket to slide off the muffler bracket, I have to remove the exhaust hanger bracket on the rear engine mount to free the muffler so I can push it down to free the rear of the master cylinder bracket.

Remove Muffler Bracket Bolts From Underneath The Muffler

Remove Muffler Bracket Bolts From Underneath The Muffler

Muffler Bracket Hardware Detail

Muffler Bracket Hardware Detail

Remove Header Pipe Bracket Nut n From Rear Engine Mount Stud

Remove Header Pipe Bracket Nut n From Rear Engine Mount Stud

Header Pipe Bracket Hardware Detail

Header Pipe Bracket Hardware Detail

The front of the master cylinder bracket is secured with an Allan bolt to bracket welded to the swing arm. I remove it.

Rear Brake Master Cylinder Bracket Front Bolt Location-Rear Brake Pedal Bushing is at Left

Rear Brake Master Cylinder Bracket Front Bolt Location-Rear Brake Pedal Bushing is at Left

Remove Rear Brake Master Cylinder Bracket Front Bolt

Remove Rear Brake Master Cylinder Bracket Front Bolt

Location of Rear Master Cylinder Front Bracket Welded to Right Side of Swing Arm

Location of Rear Master Cylinder Front Bracket Welded to Right Side of Swing Arm

Rear Brake Master Cylinder Bracket Front Bolt Detail-Note Aluminum Can Shim in Rear Brake Pedal Bushing

Rear Brake Master Cylinder Bracket Front Bolt Detail-Note Aluminum Can Shim in Rear Brake Pedal Bushing

Here is how the front bracket mounting hardware is attached.

Rear Master Cylinder Bracket, Front Mounting Hardware Detail

Rear Master Cylinder Bracket, Front Mounting Hardware Detail

Rear Master Cylinder Bracket, Front Mounting Hardware Detail

Rear Master Cylinder Bracket, Front Mounting Hardware Detail

Here is the master cylinder and bracket and the rear brake pedal assembly removed from the bike.

Rear Master Cylinder and Brake Pedal Assembly Removed

Rear Master Cylinder and Brake Pedal Assembly Removed

I use a punch to drive the rusted special pin out of the master cylinder linkage so I can remove the rear brake pedal.

Rear Brake Pedal & Master Cylinder Linkage Detail-UGLY!!!

Rear Brake Pedal & Master Cylinder Linkage Detail-UGLY!!!

Driving Brake Pedal Linkage Pin Out With a Drift

Driving Brake Pedal Linkage Pin Out With a Drift

Master Cylinder Linkage With Pin Removed

Master Cylinder Linkage With Pin Removed

Master Cylinder to Rear Brake Pedal Linkage Pin Detail

Master Cylinder to Rear Brake Pedal Linkage Pin Detail

Rear Brake Pedal to Master Cylinder Linkage Assembly

Rear Brake Pedal to Master Cylinder Linkage Assembly

At the top of the rear brake pedal is a bolt and nut that adjust when the rear brake light switch closes.

Rear Brake Pedal With Rear Brake Light Switch Adjusting Screw

Rear Brake Pedal With Rear Brake Light Switch Adjusting Screw

Rear Brake Pedal Stop Light Switch Adjusting Bolt Detail

Rear Brake Pedal Stop Light Switch Adjusting Bolt Detail

The hose from the rear brake fluid reservoir to the master cylinder is frayed so I will replace it.

Rear Brake Fluid Line Damage

Rear Brake Fluid Line Damage

The end of the hose is attached to the master cylinder with a use-once hose clamp.

Rear Brake Fluid Line Use-Once Clamp Detail

Rear Brake Fluid Line Use-Once Clamp Detail

Remove Rear Master Cylinder From Bracket

I remove the two Allan bolts that secure the rear master cylinder to the bracket. The holes in the bracket are tapped.

Remove Allan Bolts Securing Rear Master Cylinder to Bracket

Remove Allan Bolts Securing Rear Master Cylinder to Bracket

Rear Master Cylinder Bracket Bolt Detail

Rear Master Cylinder Bracket Bolt Detail

Rear Brake Master Cylinder Bracket Mounting Detail

Rear Brake Master Cylinder Bracket Mounting Detail

Rear Brake Master Cylinder Hardware Detail

Rear Brake Master Cylinder Hardware Detail

Remove Rear Disk Caliper

The rear disk caliper is on the left side and mounts with two bolts, one at the bottom of the caliper and one at the top, to a plate. The brake plate is secured around the axle and has a torque arm that attaches it to a bracket welded to the bottom left side of the swing arm. There are also two more bolts in the caliper, but these secure the two halves together and I don’t remove them. I remove the brake plate and torque arm when I remove the rear wheel.

Rear Brake Caliper Front Bottom Bolt

Rear Brake Caliper Front Bottom Bolt

Rear Brake Caliper Rear Upper Bolt

Rear Brake Caliper Rear Upper Bolt

I remove the two bolts and slide the caliper off the rear disk rotor.

Remove Rear Caliper Bolt

Remove Rear Caliper Bolt

Rear Brake Caliper Upper Bolt

Rear Brake Caliper Upper Bolt

Rear Brake Caliper Mounting Hardware Detail

Rear Brake Caliper Mounting Hardware Detail

Remove Brake Lines Between Rear Master Cylinder and Caliper

The caliper has a rubber brake hose attached to it that flexes as the swing and rear wheel move up and down. The other end of the rubber brake hose fits in a bracket and a union between it and the steel brake line coming from the master cylinder.

Rear Master Cylinder Steel Brake Line Runs Along the Front of the Swing Arm Into a Union at the Swing Arm Bracket

Rear Master Cylinder Steel Brake Line Runs Along the Front of the Swing Arm Into a Union at the Swing Arm Bracket

Remove Steel Brake Line at the Bracket

Remove Steel Brake Line at the Bracket

After I remove the steel line from the rubber hose at the bracket union, I unscrew the rubber hose from the caliper. The hose is cracked so it’s time to replace it.

Rear Brake Caliper Detail (Note the Hose is Shown Backwards, Male Thread Goes Into the Caliper)

Rear Brake Caliper Detail (Note the Hose is Shown Backwards, Male Thread Goes Into the Caliper)

Rear Brake Hose Cracks

Rear Brake Hose Cracks

The back of the caliper has a Brembo part number stamped into it.

Brembo Rear Brake Caliper Part Number

Brembo Rear Brake Caliper Part Number

The brake pads don’t look too worn, but the pad on the left is worn more than the one on the right.

Rear Brake Pad Detail

Rear Brake Pad Detail

Lastly, I remove the steel brake line and the bracket. The bracket has a rubber grommet in the hole and a square nut welded to the back of the bracket.

Remove Rear Steel-to-Rubber Brake Line Union Bracket

Remove Rear Steel-to-Rubber Brake Line Union Bracket

Rear Steel-to-Rubber Brake Line Bracket Detail

Rear Steel-to-Rubber Brake Line Bracket Detail

Rear Steel-to-Rubber Brake Line Bracket Has Square Nut Welded to Bottom

Rear Steel-to-Rubber Brake Line Bracket Has Square Nut Welded to Bottom

It takes some “dancing” to extract the brake line as one end has to clear the swing arm and the other has to clear the rear of the frame as shown in the video above and in this excerpt.

Rear Steel Brake Line From Master Cylinder Removed

Rear Steel Brake Line From Master Cylinder Removed

Here is how the bike looks now. I will remove the disk rotors when I remove the wheels and tires.

Brake System Removed (Disks Come Off When Wheels Are Removed)

Brake System Removed (Disks Come Off When Wheels Are Removed)

1 thought on “34 BMW 1983 R100RS Remove Brake System

  1. Thanks for this, most useful as I am in the process of converting my ’77 R100/7 to h/bar Master cylinder.

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