32 BMW 1983 R100RS Remove Steering Components

Now that the brake system is removed, I remove the steering components: handlebar controls, handlebar, instruments & cables.

Remove Steering Damper Knob & Dash

I start with the steering damper knob and the dash.

Ready To Remove Steering Components

Ready To Remove Steering Components

Remove Steering Damper Knob

Remove Steering Damper Knob

Front Steering Damper Knob Detail-Numbers Indicate Degree of Damping

Front Steering Damper Knob Detail-Numbers Indicate Degree of Damping

With the steering damper knob removed, the dash pulls off the handlebar as it’s secured with spring clips.

Dash Panel Removed

Dash Panel Removed

Dash Panel Secures to Handlebar with Spring Clips

Dash Panel Secures to Handlebar with Spring Clips

Remove Left Handlebar Control Assembly

The left handlebar control includes the choke assembly, the clutch switch and the clutch lever.

Remove Choke Assembly

I start by removing the choke assembly. I pry the cover plate off and then remove the large screw that secures the choke handle to the control housing.

Remove Left Handlebar Choke Assembly Cover

Remove Left Handlebar Choke Assembly Cover

Left Handlebar Choke Lever Bolt

Choke Lever Bolt

Remove Choke Lever Bolt

Remove Choke Lever Bolt

 Choke Lever Hardware Detail

Choke Lever Hardware Detail

Choke Lever Detail

Choke Lever Detail

 Choke Lever & Cable Detail-Ferrule Fits in Hole in Bottom of the Handle

Choke Lever & Cable Detail-Ferrule Fits in Hole in Bottom of the Handle

The choke cable is threaded through a slot in the control housing and the ferrule fits into a hole in the plate in the cover.

Choke Cable Detail Routing Detail

Choke Cable Detail Routing Detail

Remove Choke Cable

Remove Choke Cable

Choke Housing Detail

Choke Housing Detail

Remove Left Handlebar Control Housing

Both handlebar control bodies are secured with an Allan head pinch bolt on the bottom of the casting, I remove it.

NOTE:
The picture below shows the right handlebar control housing, but the location of the pinch bolt is the same on both handlebar control bodies.

Right Handlebar Control Allan Screw-Same as on the Left Control

Right Handlebar Control Allan Screw-Same Location as on the Left Control

Remove Handlebar Control Allan Pinch Bolt

Remove Handlebar Control Allan Pinch Bolt

The handlebar grip is attached to a plastic tube and that was glued to the handlebar. I use smooth jaw pliers to rotate the plastic tube so I can slide it off the left side of the handlebar. Then I slide the left handlebar control housing off the handlebar.

Left Handlebar Grip Mounted to Plastic Tube

Left Handlebar Grip Mounted to Plastic Tube That is Glued to The Handlebar

Smooth Jaw Pliers

Smooth Jaw Pliers

Loosening Left Handlebar Grip Assembly

Loosening Left Handlebar Grip Assembly

Left Handlebar Grip Assembly Glue

Left Handlebar Grip Assembly Glue

Sliding Left Handlebar Control Off Handlebar

Sliding Left Handlebar Control Off Handlebar

Inside the left handlebar control housing is a “perch” which is a triangular shaped piece of steel with longitudinal serrations. It is easy to loose this, but without it, the handlebar casting will rotate on the handlebar even when the pinch bolt is tight.

Left Handlebar Control Serrated Mounting Perch

Left Handlebar Control Serrated Mounting Perch

Left Handlebar Control Serrated Mounting Perch Detail

Left Handlebar Control Serrated Mounting Perch Detail

Remove Clutch Switch

I remove the clutch switch which is secured with a Phillips screw and washer.

Left Handlebar Control Clutch Switch Screw

Left Handlebar Control Clutch Switch Screw

Remove Left Handlebar Control Clutch Switch

Remove Clutch Switch

Left Handlebar Control Clutch Switch Mounting Hardware Detail

Clutch Switch Mounting Hardware Detail

Remove Left Clutch Lever

The left clutch lever is secured with a pivot bolt that I remove.

Left Handlebar Control Lever Pivot Pin

Left Handlebar Lever Pivot Pin

Left Handlebar Control Lever Pivot Pin Nut & Washer

Left Handlebar Lever Pivot Pin Nut & Washer

Remove Left Handlebar Lever Pivot Pin

Remove Left Handlebar Control Lever Pivot Pin

Left Handlebar Lever Pivot Pin Hardware Detail

Left Handlebar Lever Pivot Pin Hardware Detail

The hole in the lever the pinch bolt goes through has a plastic bushing. This often wears or cracks. I remove it and find it is broken.

Left Handlebar Lever Pivot Pin Plastic Bushing

Left Handlebar Lever Pivot Pin Plastic Bushing

Left Handlebar Lever Pivot Pin Bushing is Broken

Left Handlebar Lever Pivot Pin Bushing is Broken

Here are all the parts of the left handlebar control assembly.

Left Handlebar Control Assembly Parts Detail

Left Handlebar Control Assembly Parts Detail

Remove Right Handle Bar Control

The right handle bar control assembly includes the the brake fluid reservoir, the throttle, the front brake master cylinder, and the brake lever.

Drain Brake Fluid Reservoir and Disconnect Brake Line

Previously when I removed the brake system, I removed the brake fluid, the fluid reservoir internal parts and the rubber brake line from the master cylinder. You can see how I did that here:

Remove Throttle Assembly

I remove the cover of the throttle assembly and then the throttle cable, cam and throttle tube.

Remove Right Handlebar Throttle Assembly Cover

Remove Right Handlebar Throttle Assembly Cover

Right Handlebar Throttle Cover Hardware Detail

Right Handlebar Throttle Cover Hardware Detail

Right Handlebar Control Throttle Assembly Cover Detail

Right Handlebar Control Throttle Assembly Cover Detail

Right Handlebar Throttle Cam and Cable Detail

Right Handlebar Throttle Cam and Cable Detail

Right Handlebar Throttle Cable Detail

Right Handlebar Throttle Cable Detail

The throttle cam and the throttle tube have alignment marks to ensure the cam properly aligned with the throttle tube so the carburetor throttle linkage fully opens and closes.

Throttle Cam/Throttle Tube Alignment Marks Detail

Throttle Cam/Throttle Tube Alignment Marks Detail

The throttle tube slides off the handlebar.

Throttle Tube Detail

Throttle Tube Detail

Remove Right Handlebar Control Housing

The handlebar control housing is secured with an Allan pinch bolt on the bottom of the handlebar control housing. Both the left and right control bodies have these Allan pinch bolts in the same location.

Right Handlebar Control Allan Bolt

Right Handlebar Control Allan Bolt

Remove Right Handlebar Control Pinch Bolt

Remove Right Handlebar Control Housing Pinch Bolt

There is a triangular steel “perch” with longitudinal serrations inside opening where the handlebar goes in the handlebar control housing. This prevents the control housing from turning when twisting the throttle. The pinch bolt is insufficient to prevent the housing from turning. This is an easy piece to loose when removing the handlebar control houding from the handlebar.

Serrated Handlebar "Perch" Inside Right Handlebar Control Body

Serrated Handlebar “Perch” Inside Right Handlebar Control Housing

Serrated Handlebar Control Mounting Perch Detail

Serrated Handlebar Control Mounting Perch Detail

Remove Throttle Friction Screw and Handlebar Lever

I remove the throttle friction screw from the bottom of the right control housing. Then I remove the lever pivot pin bolt, nut and washer just as I did previously for the left handlebar control lever.

Throttle Stop Screw (Large Screw at Top) and Nut on Handlebar Lever Pivot Bolt

Throttle Friction Screw (Large Screw at Top) and Nut on Handlebar Lever Pivot Bolt

Right Handlebar Control Throttle Friction Screw Detail

Right Handlebar Control Throttle Friction Screw Detail

When I remove the handlebar lever, I remove the plastic bushing for the pivot bolt as I did for the left handlebar lever. It’s not broken, but deformed so I will replace it.

I can see the plunger for the front brake master cylinder. When you pull the front brake lever, the lever pushes the plunger into the master cylinder which pressurizes the brake fluid and that forces the brake pads against the disk rotors.

Front Master Cylinder Plunger

Front Master Cylinder Plunger

Remove Brake Fluid Reservoir

There is a Phillips screw through the master cylinder assembly that secures the plastic brake fluid reservoir to the master cylinder. I remove it.

Front Master Cylinder Fluid Reservoir Bottom Screw

Front Master Cylinder Fluid Reservoir Bottom Screw

Remove Fluid Reservoir Bottom Screw

Remove Fluid Reservoir Bottom Screw

Fluid Reservoir Bottom Screw Detail

Fluid Reservoir Bottom Screw Detail

The fluid reservoir has a pin on the bottom at the end of the reservoir closest to the handlebar lever and a cast cylinder with an o-ring that lets fluid enter the master cylinder at the other end. I use a screw driver to gently pry up the end of the reservoir with the pin. Then I rotate the reservoir back and forth while lifting it to get the cylinder with o-ring to come out of the master cylinder hole.

Pry Front Master Cylinder Fluid Reservoir Up

Pry Front Master Cylinder Fluid Reservoir Up

There is a great deal of crud underneath the reservoir. It looks like saw dust. It makes me wonder if there are termites that eat plastic 🙂

Front Master Cylinder Fluid Reservoir Has Crud Under It

Front Master Cylinder Fluid Reservoir Has Crud Under It

Front Master Cylinder Fluid Reservoir Detail-Note Mounting Pin & O-Ring

Front Master Cylinder Fluid Reservoir Detail-Note Mounting Pin & O-Ring

Fluid Reservoir O-ring & Crud

Fluid Reservoir O-ring & Crud

The passage to the master cylinder plunger is filled with goo, rust and grunge. That’s not a good sign. When I disassemble the master cylinder, I’m prepared to find the bore is rusty and pitted. If it is, I will replace it.

Master Cylinder Interior-Gunk, Rust & UGLY!!!

Master Cylinder Interior-Gunk, Rust & UGLY!!!

Remove Front Master Cylinder Assembly

I remove the master cylinder housing which is secured to the handlebar control with two Allan bolts.

Front Master Cylinder Assembly Allan Bolts

Front Master Cylinder Assembly Allan Bolts

Remove Front Master Cylinder Allan Bolts

Remove Front Master Cylinder Allan Bolts

The diameter of the master cylinder, 15 mm, is stamped on the body of the master cylinder assembly.

Front Master Cylinder Diameter-15 mm

Front Master Cylinder Diameter-15 mm

The master cylinder body is supposed to come off the handlebar control body when the two Allan screws are removed, but this one is stuck. So I mount the control body in my vice with rubber jaws and use a rubber hammer to persuade it to separate. A couple taps and it comes free. There is a washer where the plunger fits.

Freeing Master Cylinder Assembly From Handlebar Control Housing

Freeing Master Cylinder Assembly From Handlebar Control Housing

Freeing Master Cylinder Assembly From Handlebar Control Housing

Freeing Master Cylinder Assembly From Handlebar Control Housing

Right Handlebar Control Where Master Cylinder Mounts Detail

Right Handlebar Control Where Master Cylinder Mounts Detail

Front Master Cylinder Removed

Front Master Cylinder Removed

Front Master Cylinder Push Rod With Evidence of Leaking Seal

Front Master Cylinder Push Rod With Evidence of Leaking Seal

Here is the disassembled left handlebar control showing the parts.

Right Handlebar Control Parts Detail

Here is what the bike looks like now.

Ready To Remove Handlebar and Instrument Cluster

Ready To Remove Handlebar and Instrument Cluster

Remove Handlebar

The handlebar is secured to the fork top plate with risers that clamp the handlebar. The riser top piece has two studs, one longer than the other, that go through the riser bottom piece, The studs go through the fork top plate and attach with nuts on the under side of the plate.

Handlebar Risers & Instrument Housing Bracket

Handlebar Risers & Instrument Housing Bracket

Handlebar Riser & Instrument Bracket Mounting Detail

Handlebar Riser & Instrument Bracket Mounting Detail

I remove the four nuts that secure the handlebar risers.

Remove Handlebar Risers

Remove Handlebar Riser Nuts

Handlebar Riser Front Stud, Bottom Hardware Detail

Handlebar Riser Front Stud, Bottom Hardware Detail

Handlebar Riser Rear Stud Hardware Detail

Handlebar Riser Rear Stud, Bottom Hardware Detail

I pull the riser top out of the bottom releasing the handlebar. The longer stud goes through the front hole in the fork top plate.

Upper Handlebar Riser Detail

Upper Handlebar Riser Detail

Handlebar Riser Detail

Handlebar Riser Detail

Remove Instrument Housing & Bracket

The instruments are inside an instrument housing that attaches to a bracket with three Phillips screws. The bracket is bolted to the fork top plate. I loosen the three Phillips screws so I can slide the cluster off the bracket, but I don’t remove them as they fit into slots in the bracket instead of going through holes. The screws are fussy to install if they are removed as there is a plate inside the slot of the instrument housing that they thread into.

NOTE:
I previously removed the speedometer cable from the bottom of the speedometer. It has a lock nut that snugs up against the knurled threaded retainer. The 1983 RS uses an electronic tachometer so there is no tachometer cable to remove.

Instrument Housing Mounting Bolts

Instrument Housing Mounting Screws

Loosen Instrument Housing Screws

Loosen Instrument Housing Screws

Instrument Housing Mounting Screw Detail

Instrument Housing Mounting Screw Detail

Instrument Bracket Detail

Instrument Bracket Detail

The instrument housing bracket is secured to the fork top plate with two bolts. I remove them.

Remove Instrument Bracket

Remove Instrument Bracket

Instrument Bracket Bolt Hardware Detail

Instrument Bracket Bolt Hardware Detail

The bracket has four rubber bushings, two large and two small. The large ones should have a metal cap on the top and bottom, but I’m missing one of the bottom ones.

Instrument Bracket Rubber Bushing, Bottom Cover Plate-One Missing

Instrument Bracket Rubber Bushing, Bottom Cover Plate-One Missing

Instrument Bracket Large Rubber Bushing OD-25 mm

Instrument Bracket Large Rubber Bushing OD-25 mm

Inside the rubber bushings are large and small steel bushings.

Instrument Bracket Steel Bushings

Instrument Bracket Steel Bushings

Instrument Bracket Large Steel Bushing OD-12 mm

Instrument Bracket Large Steel Bushing OD-12 mm

Instrument Bracket Large Steel Bush ID-8 mm

Instrument Bracket Large Steel Bush ID-8 mm

Instrument Bracket Small Bushing OD-8 mm

Instrument Bracket Small Bushing OD-8 mm

Instrument Bracket Small Bushing ID-6 mm

Instrument Bracket Small Bushing ID-6 mm

Here is what the bike looks like now.

Handlebars & Instrument Bracket Removed

Handlebars & Instrument Bracket Removed

Remove Steering Damper Assembly

The steering damper assembly includes the black steering damper adjuster knob, the adjuster rod, the damper adjuster mechanism that mounts to the bottom of the fork lower triple clamp, and the steering damper.

Remove Steering Damper

I previously removed the black steering damper knob that is secured to the adjuster rod with a Phillips screw. Underneath the knob is a rubber bushing that fits on the end of the adjuster knob and inside the hole in the center top plate nut.

Steering Damper Knob With Damping Numbers

Steering Damper Knob With Damping Numbers

Steering Damper Stem with Plastic Bushing

Steering Damper Stem with Plastic Bushing

Steering Damper Stem Bushing Detail

Steering Damper Stem Bushing Detail

The steering damper attaches to the adjuster mechanism on the bottom of the fork lower triple clamp. If fits over a ball and is secured with a small diameter wire locking clip.

Steering Damper Adjuster Mechanism with Damper Attached

Steering Damper Adjuster Mechanism with Damper Attached

I use a small screw driver the pry the end of the clip up and out of the groove in the end of the damper rod cap. This end of the clip is on side of the cap facing the left side of the bike. I rotate the clip 180 degrees so I can pull it out of the hole it slides into on the opposite side of the damper rod cap with some needle nose pliers.

Steering Damper Front Cap Wire Retaining Clip

Steering Damper Front Cap Wire Retaining Clip

Remove Steering Damper Front Retaining Clip

Remove Steering Damper Front Retaining Clip

Remove Steering Damper Front Retaining Clip

Remove Steering Damper Front Retaining Clip

Steering Damper Wire Retaining Clip Detail

Steering Damper Wire Retaining Clip Detail

The other end of the steering damper uses the same small wire clip to attach to a ball mounted on the center tube of the frame above the horn bracket.

Steering Damper Rear Attachment Detail

Steering Damper Rear Attachment Detail

The end of the wire faces inside and is at the bottom of the cap. I remove it in the same manner as the other wire clip.

Remove Steering Damper Rear Cup Wire Retaining Clip

Remove Steering Damper Rear Cup Wire Retaining Clip

Remove Steering Damper Rear Cup Wire Retaining Clip

Remove Steering Damper Rear Cup Wire Retaining Clip

I use a screw driver to push the edge of the steering damper cap and force it off the ball inside the cap.

Remove Steering Damper Front Cup From Ball in Adjuster Mechanism

Remove Steering Damper Front Cup From Ball in Adjuster Mechanism

Steering Damper Removed From Adjuster Mechanism

Steering Damper Removed From Adjuster Mechanism

Steering Damper Removed

Steering Damper Removed

Remove Steering Damper Adjuster Mechanism & Rod

The steering damper adjuster mechanism attaches to the bottom of the fork lower triple clamp with two Allan bolts. The adjuster rod fits inside the mechanism. I remove the Allan bolts.

Remove Steering Damper Adjustment Mechanism

Remove Steering Damper Adjustment Mechanism

Steering Damper Adjustment Mechanism Hardware Detail

Steering Damper Adjustment Mechanism Hardware Detail

As I lower the mechanism, the adjuster rod comes out with the mechanism.

Removing Steering Damper Adjuster Mechanism With Adjuster Rod

Removing Steering Damper Adjuster Mechanism With Adjuster Rod

Steering Damper Rod and Adjustment Mechanism-Rod Teeth Fit Inside Teeth of the Rack

Steering Damper Rod and Adjustment Mechanism-Rod Teeth Fit Inside Teeth of the Rack

The steering damper adjuster mechanism has a rack that moves in a slot. Two spring loaded pins lock the rack into three positions, “0”, no damping, “1”, some damping, “2” maximum damping.

Steering Damper Adjuster Mechanism Detail-Note Pins Are Spring Loaded

Steering Damper Adjuster Mechanism Detail-Note Pins Are Spring Loaded

Steering Damper Rod Detail

Steering Damper Rod Detail

How Steering Damper Rod Fits Into Rack Inside Adjuster Mechanism

How Steering Damper Rod Fits Into Rack Inside Adjuster Mechanism

The steering rod has teeth cut in one end. The rod rotates as you turn the black damping control knob which drives the rack between it’s three positions.

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