At this stage in the project, the bike is apart. Last week, I took the frame, sub-frame, center stand, battery box halves, headlight ears, license plate bracket and the handlebar controls to Brad at BFN Industries, a local company near me in Arvada, CO.
Parts Ready for Powder Coating
Frame Ready for Powder Coat – Tie Wraps Indicate Threaded Holes
In the picture above, you can see the parts are in bags stored in boxes in the workshop.
The BMW panniers are from my R1150-RS which was apart until yesterday as I installed the rebuilt Ohlins shocks, updated the GPS wiring and installed a replacement HID bi-xenon bulb. As happens sometimes, all this took twice as long as I expected.
The heads are out for rebuilding and ought to be heading back from Longs Mechanical Services before too long.
I’ve been in touch with Zach at Woody’s Wheel Works here in Denver for pricing on spokes, wheel lacing and other options for the wheels. I’m still thinking about the options. I did find some nice polished stainless steel spoke kits at Hucky’s … decisions, decisions.
I’ve been working away at cleaning, restoring and polishing fasteners and assorted parts for the last month. When I get done with a set of related parts, I label a zip-lock bag and put them into the “ready to assemble” boxes. The number of parts in the “to be restored” box are dwindling, so I’m making progress on that front.
I’ve sent out orders for new parts to Hucky’s, BMW of Denver and Cycle Works in Kansas. I should have those orders in hand by the end of this week. With those parts, I should have 90% of the new parts on hand (there’s always another order it seems 😉 )
My work list is getting check marks but, there’s still a goodly number of things to work on. Here’s the current status of the work list.
| Front Wheel | ||
| √ | Remove fairing | |
| Repair fairing | ||
| Stip fairing | ||
| Paint faring | ||
| √ | Remove fender | |
| Strip fender | ||
| Paint fender | ||
| √ | Remove brake cable | |
| √ | Remove front wheel | |
| Remove tire and tube | ||
| Remove spokes | ||
| Clean & polish wheel and rim | ||
| Install new spokes OR clean old and install | ||
| √ | Inspect brakes | |
| OK | Replace brake shoes | |
| Inspect wheel bearings | ||
| Replace wheel bearings | ||
| Grease wheel bearings | ||
| Replace tire and tube | ||
| Balance | ||
| Mount | ||
| Replace brake cable | ||
| Adjust front brake | ||
| Rear Wheel | ||
| √ | Remove rear fender | |
| Strip rear fender | ||
| Paint rear fender | ||
| √ | Remove rear wheel | |
| Remove tire and tube | ||
| Remove spokes | ||
| Clean & polish wheel and rim | ||
| Install new spokes OR clean old and install | ||
| √ | Inspect rear brake shoes | |
| OK | Replace brake shoes | |
| Inspect wheel bearings | ||
| Replace wheel bearings | ||
| Grease wheel bearings | ||
| Clean & polish wheel and rim | ||
| Clean & polish rear spokes | ||
| Replace tire and tube | ||
| Balance | ||
| Install rear wheel | ||
| Adjust brakes | ||
| Front Fork | ||
| √ | Remove handlebars | |
| √ | Remove triple clamp | |
| √ | Inspect steering head bearings | |
| Replace steering head bearings | ||
| Install new bearings/races | ||
| Reassemble steering head & forks | ||
| √ | Drain and Remove forks | |
| √ | Disassemble forks | |
| √ | Replace all rubber o-rings, bushings, etc. | |
| √ | Reassemble forks | |
| Controls | ||
| √ | Remove rider foot pads | |
| √ | Remove brake cable | |
| √ | Remove clutch cable | |
| √ | Remove throttle cables | |
| √ | Remove choke cables | |
| √ | Remove handlebar grips | |
| √ | Remove handlebar controls | |
| Powder coat handle bar perches | ||
| Strip and Paint switch covers | ||
| √ | Remove handle bars | |
| Replace handlebars | ||
| Polish mirrors | ||
| Polish control levers | ||
| Install handle bars | ||
| Install handlebar controls | ||
| Install brake cable | ||
| Install clutch cable | ||
| Install throttle cable | ||
| Install handlebar grips | ||
| Engine, Clutch | ||
| √ | Remove Carbs | |
| √ | Rebuild carbs | |
| Clean & polish air tubes | ||
| √ | Clean & polish hose clamps | |
| √ | Remove air box halfs | |
| √ | Clean and polish air box halfs | |
| √ | Remove starter cover | |
| √ | Clean and polish starter cover | |
| √ | Remove valve cover | |
| √ | Remove head | |
| √ | Remove cylinder | |
| √ | Rebuild head | |
| √ | Remove piston | |
| √ | Remove rings | |
| √ | Remove engine | |
| √ | Clean piston | |
| Measure cylinder bore | ||
| Gap new rings | ||
| Install new rings | ||
| Remove clutch | ||
| Inspect clutch for wear and condition | ||
| Remove flywheel | ||
| Refresh paint on timing marks | ||
| Replace Rear Main Seal | ||
| Replace Oil Pump Seal | ||
| Assemble flywheel and clutch | ||
| Remove oil pan | ||
| Clean & polish oil pan | ||
| Inspect screen | ||
| Install new pan gasket | ||
| Replace cam shaft seal | ||
| Clean and polish engine case | ||
| Install cylinder base gasket | ||
| Install push rod tube bushings | ||
| Install cylinders | ||
| Install pistons | ||
| Install head gasket | ||
| Install heads | ||
| Set valves | ||
| Install valve cover gasket | ||
| Install valve covers | ||
| Install carbs | ||
| Balance carbs | ||
| Set timing | ||
| Transmission | ||
| √ | Remove transmission | |
| Clean and inspect | ||
| Replace clutch throw-out felt, gaskets, seals | ||
| Lube splines | ||
| Install transmission | ||
| Install new speedometer cable | ||
| Install new clutch cable | ||
| Tank | ||
| √ | Remove tank | |
| Strip tank | ||
| Paint tank | ||
| √ | Remove petcocks | |
| √ | Rebuild petcocks | |
| Install petcocks | ||
| Install tank | ||
| install new fuel lines | ||
| Install new air cleaner | ||
| Install air box and starter cover | ||
| Frame | ||
| √ | Remove seat | |
| √ | Remove side panes | |
| Strip and paint side panels (Blue Stripes) | ||
| √ | Remove front foot pegs | |
| √ | Polish pegs | |
| Install footpeg rubbers | ||
| √ | Remove rear foot pegs | |
| √ | Polish pegs | |
| Install footpeg rubbers | ||
| √ | Remove side stand | |
| √ | Clean, polish side stand | |
| √ | Remove center stand | |
| √ | Remove shocks | |
| Clean and polish shocks | ||
| Clean and polish shock covers | ||
| √ | Remove battery box | |
| Powder coat battery box | ||
| √ | Remove battery | |
| Replace battery | ||
| Replace (+) and (-) cables | ||
| √ | Remove rear frame | |
| Powder coat rear frame | ||
| √ | Remove Rear Turn Signals & Tail light | |
| Clean and polish turn signals | ||
| Strip and paint brake light | ||
| √ | Replace turn signal stalk | |
| √ | Remove swing arm | |
| Strip paint | ||
| Paint swing arm | ||
| √ | Remove electrics | |
| √ | Remove wiring harness | |
| √ | Remove headlight shell | |
| Powder coat frame | ||
| Powder coat sub-frame | ||
| Powder coat battery box | ||
| Powder coat license plate braket | ||
| Powder coat center stand | ||
| Assemble center stand | ||
| Assemble electrics | ||
| Mount wiring harness | ||
| Mount engine in frame | ||
| Mount side stand | ||
| Assemble oil filter and cover | ||
| Mount transmission to engine | ||
| Lube output shaft splines | ||
| Mount swing arm | ||
| Assemble rear frame | ||
| Assemble shocks | ||
| Mount Seat | ||
I started with a work list when I was planning the build and I update it periodically as I go. It keeps getting longer, but the rate of increase slowing down 🙂
The budget estimate at this point is on the order of $3,700 to finish the project. I wouldn’t be surprised to see that number go up by 25% which is the nature of these projects. There’s always something else you didn’t expect, isn’t there?