And Now For Something Completely Different-2004 R1150GS Fuel Filter Replacement

I recently renamed this site “Brook’s Airhead Garage” in recognition that over the almost 10 years since I started it, 95% of the content is about how to rebuild, restore and care for BMW airhead motorcycles.  So what happens? A friend, Rohn, talked me into doing a 72,000 mile service on his 2004 R1150RS.

I too own a 2004 R1150, but mine is an RS. Generally I’ve had a dealer do most of the routine maintenance on it. Although, I have told myself that I ought to broaden my horizons mechanically and become more knowledgeable about it’s maintenance. Rohn’s request pushed me over the edge.

In researching the work required for this service and the history of work done on Rohn’s bike, I noted that his fuel pump is original. Mine died at about 75,000 miles in Des Moines, IA at the intersection of I-35 and I-80 in a construction zone on my way to Michigan. Unlike an airhead, there wasn’t a thing I could do to coax it back to life.  I told Rohn he might consider his fuel pump and the internal hoses  a “preventative maintenance” item and he agreed to have me replace it.

In looking around for information on the internet, and YouTube, to prepare me for this work, I wasn’t able to find good instructions for replacing the fuel pump. There are several resources that show how to replace the filter, but the fuel pump seemed to be left out.

So, I put this material together to fill that gap.


Musing: The Joys of Being A Minimalist

A minimalist is someone who follows this creed,

“Everything should be made as simple as possible, but not simpler.”, A. Einstein.

It is a “scientific” creed similar to Occam’s razor summarized as, “The simplest explanation is usually correct.” These two guiding principles provide direction when you are looking for explanations and aren’t sure how to proceed. But, they also underpin a philosophy of design that creates unadorned, straightforward products that are a delight to experience.

My appreciation of BMW airhead motorcycles is a practical expression of Einstein’s prescription of what the result of science should look like. Airhead design is functional, not elaborate nor flamboyant. The styling relies on form following function for its appeal, not on plastic panels and extraneous amenities that distract from the direct understanding of how the machine works. Even when BMW introduced the first motorcycle with a manufacturer integrated full fairing in 1977, the R100RS, the shape of the fairing was defined by aerodynamic necessity and the requirement to protect the rider from adverse weather. I think the RS fairing is a design that solves several hard problems as simply as possible, but no simpler.

For BMW airheads, the art in the design lies in engineering control of material properties and precision machining during manufacture. For example, machined tapers with press fits are preferred to castle nuts with tab washers when connecting driven components on a turning shaft. Parts inventory is minimized and the assembly procedure is simple.

Another example is the tool kit that comes with the bike. With it, you can disassemble just about anything on the motorcycle. I’ve used the tool kit to remove the top end to replace rings and then reassemble it. I have removed the transmission, the drive shaft, the entire rear sub-frame and the rear wheel with it. Nothing else in my tool box was required. That lowly, hidden tool kit is an elegant expression of the minimalist mindset.

The joy of motorcycling comes from a direct, frictionless connection between mind and action, but that is deepened when the machine you are riding is an elegant execution of the minimalist creed espoused by Einstein.

I think that’s why I got so involved in airhead wrenching over the last decade.

Maryland Airheads SuperTech 2.2

Out of the blue last November, I received an email from Maryland Air Marshal, Will Andalora, asking if I would be willing to be their special guest at the 2017 SuperTech 22.  To say the request was unexpected is an understatement. I called Will and after he assured me there was no mistake, it was me they wished to invite, he talked about his expectations and I accepted the invitation.

Will encouraged me to come out early so I could see some airhead sites before SuperTech started on Friday night. So, on Wednesday morning, I flew from my home in Colorado to Baltimore where Mark Lipschitz picked me up and took me to his home. I met the merry band of Maryland airheads who put this extravaganza of Air Head goodness together; Will Andalora, Mark Lipschitz, Bill Lambert, Jim McKinna. Also joining us was Chris Kennedy who puts on the “Techno Barn” Tech Day. They came over to Mark’s house where we enjoyed home cooked specialties of the house. By the end of the evening, I felt like family.

Thursday was set aside to visit two museums catering to BMW motorcycles, ephemera, lore and to experience the passion of those who love collecting all things BMW Motorad and hearing the stories of how they came by the many items they had collected. The first stop was Jim Hopkin’s home. Jim has pursued photographs, clothing, pins, badges, trophies, bikes, toys, sculpture, and paintings all accompanied by fascinating accounts of his hunts around the world for this cornucopia of BMW motorcycle objects. Jim has one of the original M2B15 flat twin BMW engines supplied to the Victoria motorcycle company for use in their KR 1 motorcycle in the early 1920’s, letters, awards and trophies from racing legends, women riders and racers, and those who guided the destiny of BMW’s motorcycles.

BMW First Flat Twin Engine-M2B15 Used by Victoria in Their KR 1 Motorcycle

1920’s Race Leathers

airheaeds pre super tech
Motley Airhead Gang Poses at Jim Hopkins’ Museum for A Group Mug Shot

Here is a slide show of the pictures I took at Jim’s place.

And a short video of a neat toy BMW that reminded me of toys I played with in the 1950’s.

And a video of a distinctive sculpture Jim commissioned. The artist uses junk from automobile junk yards.

We then met Bob Henig, owner of Bob’s BMW, for lunch followed by a tour of his museum. Bob’s collection of BMW motorcycles is on two floors. I’m working on rebuilding a 1977 R100RS and he has one in his collection so I took some photos of the details I wasn’t sure about.

Bob Henig Leading the Way into His Vintage BMW Museum

Bob has an R32, several famous race bikes, iconic models and even a single wheel MV Agusta.

First BMW Bike, Model R32
1925 R32 in Front of the Iconic K1

1984 Krauser MKM 1000/4
1984 Krayser MKM 1000/4

1970 R75/5 Land Speed Record Bike
1970 BMW R75/5 Land Speed Record Bike

1950’s MV Agusta 60 cc Monomoto Superleggera
1950’s MV Agusta 60 cc Monomoto Superleggera

Here is a slide show of the pictures I took at Bob’s museum.

Friday afternoon was spent setting up for SuperTech at the Tuckahoe Steam and Gas museum including unloading all the cut-away models Bob Sipp brought and getting a guided tour of the machine tools museum. This collection goes back to the beginning of the 20th century. The tools work and many are powered by overhead shafts with belts and pulleys.

Site of SuperTech 2.2 Meeting
Tuckahoe Steam and Gas Association Facility in Maryland-Home for SuperTech 2.2

Just a Few of the Many Machine Tools in the Working Museum

Here are two short videos of the inside of the machine shop. The second shows the overhead shaft and pulley system operating.The overhead shaft and pulley system used to distribute power to the old machine tools that did not have separate electric motors. This was a common method of distributing power in factories at the end of the 19th and early 20th century.

SuperTech has a fantastic collection of cut-away models. This is just one them, a beautifully done cutaway of a Bing carburetor.

One of Three Bing Carburetor Cut-away Models Bob Sipp Brought

Friday evening starts the festivities for the 65 attendees who came from as far away as California with pizza, BYOB, lots of introductions, conversations and a short presentation about how my motorcycling life led me to start rebuilding airhead bikes in earnest in 2009 and documenting the work on my web site, “Motorcycles and Other Musings”.

Some of the Airhead State Flags From Those in Attendance
State ABC Flag Display

Friday Night Pizza & BYOB
Friday Night at the Hotel for Pizza, Beer and Comradery

The format for Saturday included technical, product and riding adventure presentations. The new Kat Dash instrument flex-boards (Kat and Paul Connell), how ethanol affects our bikes (Bill Lambert), the mental preparation for a good ride (Mike Friedle), understanding electricity and wiring systems (Bill Dudley), high mileage riding (Ed Fule), stump the expert (Tom Cutter), a seminar on the on-board toolkit, bike parts and roadside flat tire repair.(Will Andalora), bringing an R75/5 back to life (Dave Fish), details about new replacement wiring harness (Todd Millican) and the story behind the “Motorcycles and Other Musing” web site (Brook Reams). Dinner was served, BYOB was consumed and conversations broke out like daffodils after the spring thaw.

Me and Ed Fule with Our Presenter Aprons
The Author and Ed Fule Wearing Presenter Aprons and Enjoying the Spring Day

Paul and Kat Connell Making Their Presentation in Stereo
Paul and Kat Connell’s Presentation Was in “Stereo”

Dave Fish Rode This Bike To SuperTech
Dave Fish Rode his Presentation Bike to SuperTech

Sunday morning started off with a presentation by Jim Hopkins of the story behind his museum. He captured the imagination and commanded the complete attention of everyone in the room with his slides and storytelling.

Jim Hopkins Presentation on His Museum and His Passion
Jim Hopkins’ Stories Command the Rapt Attention of the SuperTech Audience

At the wrap up, the coveted Dung Beetle award was presented to our Airstore manager Dave Cushing.

Coveted Dung Beetle Award
The Coveted Dung Beetle Award

This is a slide show of pictures I took during SuperTech 2.2

BMW Fairing Plastic Repair with Plast-Aid

My R1150-RS had a minor tip over, but it broke the upper fairing and also cracked one of the tabs that the left, front turn signal screws into. 🙁

Cracked Upper Fairing

Cracked Upper Fairing

Broken Tab for Turn Signal Mounting Screw

Broken Tab for Turn Signal Mounting Screw

I used Plast-aid to attach the wiring bulk head connector in a Windjammer II fairing with great success. Vetter used ABS plastic in the Windjammer fairings. I believe BMW is using ABS or a similar plastic for the body work, so Plast-aid will work well with it. It worked so well on the R1150-RS repair that a few months later, I used it to repair a number of cracks in BMW touring cases (aka, Krauser panniers).

Repairing Broken Screw Tab

I use a washer to help reinforce the srcew tab. Plast-aid will mechanically bond to steel, particularly if it has been roughed up with 100 grit wet/dry paper.

Tab Piece, Washer for Reinforcement and Mounting Screw

Tab Piece, Washer for Reinforcement and Mounting Screw

I mix up a small amount of Plast-aid. It changes consistency as the chemical reaction progresses. I wait a minute or two until it is the consistency of pancake batter. While I wait, I put some of the liquid component on the edge of the tab and the remaining edge on the fairing to promote good adhesion. When the Plast-aid has stiffened a bit, I put some on the edge of the broken tab. I hold it against the remaining tab surface of the fairing until it stays put, about 2 more minutes. I use the rest of the Plast-aid, smear some on the washer and the apply it to the back side of the tab for reinforcement. I hold this in place for another couple of minutes and I’m done.

Reinforcing Washer Glued On

Reinforcing Washer Glued On

Repairing Cracked Fairing

The fairing crack repair needs reinforcement. I use a small piece of fiber glass mat and shape it to fit behind the crack. There is a small brace above the crack that reinforces the other screw hole for the turn signal and I anchor the fiber glass against it and down across the crack.

Fiberglass Cut to Size For Reinforcement

Fiberglass Cut to Size For Reinforcement

I mix up a larger amount of Plast-aid and apply some of the liquid component along the edge of the crack to improve adhesion . I put some on the edge of the crack, aline the edges so they are tight and put some masking tape over the crack to hold the pieces together.

Masking Tape to Hold Edges Together

Masking Tape to Hold Edges Together

I put the fiber glass into the Plast-aid when it is the consistency of Elmer’s Glue to soak some into the openings of the fiber glass. I put it on the back side of the fairing, and add some more Plast-aid using a Popsicle stick. I have to hold the patch in place for a minute or so using a finger and the Popsicle stick. When it becomes very firm and the fiber glass stays put, I’m all done.

Plast-aid Soaked Fiberglass On the Back Side of Crack

Plast-aid Soaked Fiberglass On the Back Side of Crack

Here is the final repair. It will need to be sanded, some bondo used to fill in the scratches and painted. But that’s a job for another day when I setup my temporary paint booth again.

Final Repair-Just Needs Painting

Final Repair-Just Needs Painting

Blog Metrics and Plans for 2015

Blog Metrics So Far

So, I’ve been pretty inactive in this blog since July of 2014 when I finished the rebuild of “Grover”, a 1973 BMW R75/5 that I worked on over an 18 month period.  But, you haven’t. As the picture below shows, monthly visits to this site have gone way up since I started posting my progress on that project starting in December of 2012 and continued to stay high after the project completed on July 4, 2014.  The material I’ve posted is averaging 5,500 to 6,000 visits a month.


I never expected that much interest, but it shows the power of the internet as a low cost way to find information anywhere in the world.  In looking at statistics about where people come from and sites that have linked to this content, folks in Australia, Brazil, England, Finland, France, Germany, New Zealand, Russia, Scotland, Singapore, Slovenia, South Africa, Sweden, and Switzerland have visited.

The top 11 most popular write-ups with their [number of visits] are:

The carburetor rebuild work is actually represented twice; the highest hit rate was for the work write-up and the other was for the blog post announcing the availability of that write-up.

Plans for 2015

I’ve had a list of bikes for my next project and have been cruising Craig’s List, BMW MOA, and Google searches for one of the following bikes.

  • R69S
  • R90S
  • R80/7
  • R80RT
  • R80ST
  • R100RS
  • K75S

This week, I’m finalizing the purchase of a 1983 R100RS with 83,000 miles. My plan is to rebuild this bike and document my work as I did for the R75/5 project.  So, there will be more blogs and write-ups coming soon. 🙂

I’ve become pretty active in the Airheads Beemers Club in Colorado (ABC-CO). I helped start a Down to Meet site to promote all things Airhead. If you live in the state, or are passing through, please join one of our “Parking Lot Universities (PLU)”, “Ride-to-Eat (RtE)” and our annual Tech Day which is held in April.

One idea I have is to create some PLU activities using my garage (so more of a BGU) so Airheads who want to learn more about the R100RS can participate, grab a wrench, or just hang out as I work on this project. It should be fun.