1983 BMW R100RS Remove Brake System

I removed the twin front disk brake system and the rear single disk brake system. The rear brake pedal assembly had a kludge repair to fix the wobbling brake lever. And, the rust was so bad on the rear master cylinder linkage that I couldn’t remove the rear brake pedal and had to remove the master cylinder and rear brake pedal together.

You can see how I did this work here:

I shot some short videos of how all the brake system components are connected together.

VIDEO: 1983 BMW R100RS Front Brake Assembly

VIDEO: 1983 BMW R100RS Rear Master Cylinder Assembly

VIDEO: 1983 BMW R100RS Rear Brake Caliper Assembly

Here is what the bike looks like now. I will remove the disk rotors after 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)

1983 BMW R100RS Remove Electrical System

After I removed the fairing and rear fender assembly, I removed the electrical system including the main and sub wiring harnesses and the electrical components attached to the frame.

As I did this work, I put together a video tour of the electrical system.

VIDEO: Remove Electrical Wiring & Components

And, you can read all about how I did this work here.

Here are a couple pictures from this document.

Main Harness Zip Tie Location

Main Harness Zip Tie Location

Location of Clutch Switch and Front Brake Switch Sub-harness Connectors

Location of Clutch Switch and Front Brake Switch Sub-harness Connectors

Main Harness Leads Near Left Coil

Main Harness Leads Near Left Coil

Ignition Module with Connector On Top of Front Brake Manifold

Ignition Module with Connector On Top of Front Brake Manifold

Main Wiring Harness Removed

Main Wiring Harness Removed

CO-ABC Tech Class on Spline Lube and Swing Arm Bearing Replacement

I’ve been hosting tech classes for the Colorado Airhead Beemers Club using my small workshop, affectionately called “Brook’s Airhead Garage”. If you live in Colorado and want to join our Down To Meet group, click here and join.

–> Colorado Airheads Beemer Club (CO-ABC) Down to Meet Site

It is a way to help disseminate knowledge about the care and feeding of these 40+ year old motorcycles. I’m hopeful that the more our members know, the more inclined they will be to do their own work, and the longer these motorcycles will keep running.

Last Saturday, one of our members, Chris, brought his 1974 R90/6 in so he can learn-by-doing. We had about 10 others come to lend a hand, kibitz and hang around with like-minded folks.

I wrote up a check list for Chris on how to do this work.

Transmission Spline Lube & Swing Arm Bearing Replacement

Transmission Removal, Lube, Install

  1. Remove air intake tubes and carburetors (leave cables on carbs).
  2. Remove air box clam shells and air filter (leave choke lever connected)
  3. Remove battery
  4. Remove battery box
  5. Remove drive shaft bolts (4)
  6. Remove luggage rack (if attached)
  7. Remove rear brake rod
  8. Remove rear wheel
  9. Remove shocks (not needed if all you do is a spline lub)
  10. Remove drive shaft front nuts (4)
  11. Remove swing arm pivot pins
  12. Remove swing arm
  13. Remove transmission bolts (3) and nut (1)
  14. Slide transmission off splines (protect frame tubes from scrapes)
  15. Inspect & clean splines
  16. Lube splines with Honda Moly 60 paste (or Honda Moly 77 paste)
  17. Slide transmission back on splines
  18. Attach transmission bolts (3) and nut (1) & torque

Swing Arm Bearings Removal

  1. Remove dust caps
  2. Remove inner bearing race
    1. Inspect for brineling to outer race and/or damage to inner race
    2. Replace if necessary
  3. If replacing swing arm bearings, pull outer races with Cycle Works bearing puller.
  4. Install new outer races with Cycle Works tool
  5. Pack inner bearing race with red LP-2 grease
  6. Install inner bearing race
  7. Install dust cover

Swing Arm Installation

  1. Install swing arm pivot pins
  2. Install drive shaft bolts (4) to transmission output coupling
  3. Center swing arm
  4. Torque swing arm pivots and lock nuts
  5. Recheck swing arm is centered

Final Assembly

  1. Inspect rear drive splines. Clean and lube with Honda Moly 60 or Moly 77 paste.
  2. Install rear drive on swing arm with new gasket and (4) bolts and washers and torque
  3. Install shocks and torque
  4. Install luggage rack (if used)
  5. Install rear wheel and torque nut
  6. Install rear brake rod and adjust rear brake
  7. Install battery box
  8. Install battery
  9. Install air box filter and clam shells
  10. Install carburetors and inlet air tubes

It took about 6 hours to complete this work including a pizza lunch and the general banter that takes the place of wrench twisting at these gatherings.

1983 BMW R100RS Remove Rear Fender Assembly

I’m making progress on getting to where I can remove the electrical system. I finished taking off, and taking apart, the rear fender assembly that includes the license plate bracket with side reflectors, tail light housing, turn signals and stalk, the cowling tool box and the rear wiring sub-harness.

You can see what I found and how I did the work here.

Rear Tail Light, & Turn Signal Assembly, License Plate Bracket & Rubber Mud Flap

Rear Tail Light, & Turn Signal Assembly, License Plate Bracket & Rubber Mud Flap

Tail Light Reflector Wiring Detail

Tail Light Reflector Wiring Detail

Rear Wiring Sub-Harness Plug Location

Rear Wiring Sub-Harness Plug Location

Rear Fender Assembly Removed

Rear Fender Assembly Removed

1983 BMW R100RS Remove Tank, Seat & Fairing

Due to the blizzard in Denver yesterday, I had time to finish up some documentation on the project so far and post it to my site. The focus has been on the fairing disassembly and a catalog of the fairing mounting hardware and where it goes. I found existing parts fiche aren’t very helpful about what fasteners go where.

Here is a link to two new publications.

52 BMW 1983 R100RS Remove Seat and Seat Cowling
46 BMW 1983 R100RS Remove Fairing, Dash, Volt Meter, Clock, Ignition Switch

I included a couple videos, one of which shows details of how all the fairing panels are connected.

Here is how the bike looks now.

Tank, Seat, Fairing & Brackets Removed

Tank, Seat, Fairing & Brackets Removed

And the stack of bins the parts are going in, which will increase as I get down to the frame.

Bins for Disassembled Bike Parts

Bins for Disassembled Bike Parts