Category Archives: MC Build Projects

Chronicles of my Motorcycle Build Projects

1973 BMW R75/5 Rebuild: Install Front Brakes

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More progress being made on the project with the new front brakes, brake cable & handlebars installed.  You can read about how I did that here.

Thanks to Bob Fleischer, again, for tips and tricks and to Duane Ausherman.

I found a nifty template from Scott Lydiard (BMWScotter.com) that helped get the front brake levers aligned correctly on the brake levers.  Scott’s site is having some problems but he was kind enough to provide a PDF of this template that I provide a link to in the write-up.  Here’s a picture of the template.

Scott Lydiard's Brake Lever Alignment Template

Scott Lydiard’s Brake Lever Alignment Template

You can cut it out and use it with the brakes installed.

Using Scott Lydiard's Front Brake Lever Alignment Template

Using Scott Lydiard’s Front Brake Lever Alignment Template

Very nice.

Here are a couple more pictures from the write-up.

Front Brake Carrier (Front to the Right)

Front Brake Carrier (Front to the Right)

Front Brake Assembly

Front Brake Assembly

Rear Brake Cam Shaft Lever and Adjustment Cam

Front Brake Arm Cam with Lever and Adjustment Cam

Front Spring Installed and Shoes on Pivot Pins

Front Spring Installed and Shoes on Pivot Pins

Attaching Rear Spring Using Vice Grips

Attaching Rear Spring Using Vice Grips

Front Axle with Spacer Sleeve

Front Axle with Spacer Sleeve

Connecting Front Brake Arm

Connecting Front Brake Torque Arm to Brake Carrier Stud

Brake Cable Assembly at Right Control Perch

Brake Cable Assembly at Right Control Perch

Inserting Ferrule in Rear Brake Lever to Capture Outer Sleeve of the Cable

Inserting Ferrule in Rear Brake Lever to Capture Outer Sleeve of the Cable

Adjusting Lower Cable

Adjusting Lower Cable

Brakes Are Solid at 1/2 Distance to Handlebar

Brakes Are Solid at 1/2 Distance to Handlebar

1973 BMW R75/5 Rebuild: Install and Align Front Forks

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So, now I’m ready to install the front forks and align them. You can read about how I did that work here.

Earlier, I rebuilt the front forks, refinished the sliders and replaced the steering head bearings. I also polished the steering damper knob and added a modern BMW emblem to the center of the knob. You can read about how I did that here:

It took me awhile (about 2 weeks) to complete the fork tube alignment process. I had to adjust the forks to get them parallel in both the X and Y Planes. And then they went out of parallel as I assembled the upper top brace and the headlight ears.  Some investigation showed that the rubber gaskets on the headlight ears changed the alignment of the upper brace. Small changes create misalignment, so patience is a virtue.

I’m pleased with the final product both in looks and improved alignment.

Here are a couple pictures from the write-up.

Steering Head after New Bearings Installed

Steering Head after New Bearings Installed

Fork Sliders, Top is Right Side, Bottom is Left Side with Axle Clamp Allen Head Screw

Fork Sliders, Top is Right Side, Bottom is Left Side with Axle Clamp Allen Head Screw

Forks Mounted and Lower Sliders Removed

Forks Mounted and Lower Sliders Removed

Positioning Glass on Fork Tubes

Positioning Glass on Fork Tubes for Y-Plane Alignment

Fork Alignment in Y-Direction

Fork Alignment in Y-Direction

X-Plane Measurement at Bottom of Tube

Fork Alignment in X-Direction

Clamping Forks Below Yolk to Adjust X-Plane Alignment

Clamping Forks Below Yolk to Adjust X-Plane Alignment

Lowers with Fork Brace Installed

Lower Slider with Fork Brace Installed

Steering Head Grunge & Damper

Original Steering Head Grunge and Scratched Damper Knob

Polished Damper Knob, Emblem and Polished Upper Brace

Polished Damper Knob, Emblem and Polished Upper Brace

Finished Upper Fork Brace with Damper and Handlebar Mounts

Finished Upper Fork Brace with Damper and Handlebar Mounts

Finished Upper Fork Brace with Damper and Handlebar Mounts

Finished Upper Fork Brace with Damper and Handlebar Mounts

1973 BMW R75/5 Rebuild: Some Refinishing Information

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I’ve had several questions and Email about how I refinish the rough aluminum casting on the engine, transmission and rear drive and also some questions on how I got the carburetors to look shiny and new again.

NOTE: Refinishing is not rebuilding. Refinishing is restoring the surface of parts to “like new” condition. You are removing crud, stains, grime, dirt, grease, bugs, corrosion, tar, mud and old gasket sealer that have frequently been baked on for 10, 20, 30 or more years. It takes PATIENCE. It is applied Zen Smile

So, I put this together to illustrate some of the techniques I use on this project:

And, some After pics from the write-up:

Polished Hubcaps

Polished Hubcaps

New Rubber, New Spokes & Polished Wheels

New Rubber, New Spokes & Polished Wheels

Polished Engine

Refinished Engine Case and Timing Cover

Refinished Left Side

Refinished Transmission

Cleaned and Polished, Outside View

Cleaned and Polished, Outside View

Powder Coated Right Control Perch with Polished Lever

Powder Coated Right Control Perch with Polished Lever

1973 BMW R75/5 Rebuild: Installing Rear Sub-Frame, Shocks, Key Lock, Seat Latch

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This bit of work finishes up the rear end until I install the fenders and seat. Those will wait for me to strip and paint the body work.

Here is a write-up on this work.

The key lock and seat latch can be confusing to get in, so I took some extra pictures of the assembly process.

Here’s a couple pictures from the write-up.

Rear Frame

Rear Sub-Frame, Upside Down

Marking on Right Shock Pre-Load Adjuster

Marking on Right Shock Pre-Load Adjuster

Securing Shocks by Lower Shackle

Securing Shocks by Lower Shackle

Right Side Sub-Frame Bolts Installed

Right Side Sub-Frame Bolts Installed

Seat Latch and Lock Hardware

Key Lock and Seat Latch Hardware

Attaching Lock Retaining Ring with Screw

Attaching Lock Retaining Ring with Screw

Here is the rear end of the bike when I disassembled it.

Rear End Disassembly

Rear End Disassembly

Supporting the bike before rear end and swing arm removal

Rear End Dissassembly

And how it looks now. Major improvement 🙂

Rear Shocks Installed

Final Product

Lock & Grab Handle

Key Lock and Grab Handle Installed

1973 BMW R75/5 Rebuild: Rear Brake Installation

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Well, I now have the rear brakes installed and am working on getting the rear sub-frame on the bike. When I get that done, I’m going to move on to the front forks and steering.

Here is the write-up on installing the rear brakes, rear brake pedal and mounting the polished rear wheel with the new stainless steel spokes and the powder coated battery box:

Here’s how the bike looks at this point.

Rear Brake Pedal and Wheel Installed

Rear Brake Pedal and Wheel Installed

Final Result

Final Result