I installed the rear fender assembly that includes the rear turn signals, tail light and brake light housing, the fender, mud flap and license plate bracket with side reflectors. This is easy work if you remove the rear wheel. But, there is a lot of hardware used and I show what goes where.
This is a link to the detailed documentation and a short video summarizing the work.
I’m converting this RS model to a RT. The only difference in the brake system is the length of the hose from the front master cylinder to the front brake line manifold underneath the gas tank (RT: Part# 34 32 1 241 565; RS: Part# 34 32 1 241 564). Since the RT handlebars are wider, that hose is longer. The rear brake system is the same on both the RS and RT models.
Here is a link to the documentation of how I do this work.
And this is a short video summarizing the procedure.
VIDEO: 1983 BMW R100RS/RT Install Front Brake System
I previously rebuilt the two front and one rear calipers and rebuilt the rear master cylinder. The front master cylinder was so badly corroded that I replaced it along with the entire right handlebar perch. I also installed the three disk brake rotors on the newly powder coated wheels. You can read about how I did that work here.
I opted to use the mechanical front brake switch that mounts in the right perch instead of the original brake fluid pressure switch that mounts on the rear of the front brake manifold under the gas tank. The hole in the pressure switch can trap an air bubble making it more difficult to bleed the brakes.
I plugged the rear hole in the front brake line manifold where the front brake light pressure switch mounts. McMaster-Carr sells a plug with copper crush washer that’s perfect for this.
McMaster-Carr Stainless Steel Plug With Copper Washer
Stainless Steel Plug Installed In Front Brake Line Manifold Hole For Pressure Switch
I now have brakes and the bike is getting pretty close to being finished.
I’m converting this RS model to a RT. The only difference in the brake system is the length of the hose from the front master cylinder to the front brake line splitter underneath the gas tank as the RT handlebars are wider so that hose is longer. The rear brake system is the same on both the RS and RT models
I previously rebuilt the two front and one rear calipers and rebuilt the rear master cylinder. The front master cylinder was so badly corroded that I replaced it along with the entire right handlebar perch. I also installed the three disk brake rotors on the newly powder coated wheels. You can read about how I did that work here.
VIDEO: 1983 BMW R100RS/RT Install Rear Brake System
The master cylinder in on the right side while the rear brake caliper is on the left so there is a long steel brake line between the master cylinder and a bracket on the left, lower frame gusset where the flexible brake hose from the caliper attaches to the steel brake line. That’s a long run of brake line and I use my “Air Zapper” to help pull the air out of the line.
“Air Zapper” Vacuum Brake Bleeding Parts
I finished up bleeding the rear brake system by pumping the rear brake pedal and opening and closing the caliper bleed valve to get the last bit of air out of the system. I now have a solid rear brake all set to stop.
I’m converting this bike from and RS to an RT model, so there are some changes associated with the RT model, but the electrical system changes are limited to changes in cable lengths for the handlebar switches.
This document references other documents previously published as well as containing new material.
The idea is to consolidate information about how I install the electrical system on the bike in one place. I also include the results of my testing of the electrical system, the problems I found and how I fixed them. I hope this is helpful.
On this model/year bike, it’s critical to shim the oil filter canister correctly to avoid loss of oil to the engine. I show how I do that. I also show how I install the oil cooler, thermostat-oil filter cover, and the shims and o-rings to properly seal the cover and oil filter canister.
