The New And Improved Unofficial R65 Forum V2
Technical Discussion => BMW Technical Q&A, Primarily R65 => Topic started by: Tony Smith on February 22, 2016, 06:01:12 AM
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Saturday afternoon I started what I thought would be a simple and uncomplicated job.
The objectives were:-
1/. Pull the forks apart and replace the missing damper rod piston rings
2/. Make up a pair of 3/4" spacers and fit them above the fork springs
3/. Fit my new Betor shock-absorbents.
The best laid plans.......
Pulling the forks apart I managed to lose one of the circlips on the bottom of the fork. I am usually extremely careful of such things, but the dog chose that precise moment to give me a "hello boss" tongue in the ear which caused me to lose concentration. The clip hit the floor and bounced, I listened carefully for the landing so I'd have a rough idea where to start looking, but I didn't hear it. The workshop/carport can be a very big area when you are searching it on your hands and knees. After 40 minutes I gave up and headed into town, luckily catching a car parts place just before they closed, even more luckily they had a selection of circlips in a blister pack with one the right size. Yay.....
Went home and changed back into work clothes - then I could not find the blasted piston rings. A few months ago I bought 8 brand new ones and fitted 6 of them to the wife's R65/80 because I damaged two of hers the last time I pulled the forks apart, I kept the good second hand ones (which allegedly are better quality) for use in my R65 which I knew was also missing 2 rings.
After 35 minutes searching for the plastic bag with the damper rod rings in it I gave up and went upstairs to shower and get ready to go out. Just as I turned the shower on I remembered where the blasted things were
Next morning I fitted the rings and reassembled the forks, I then cut to 3/4" spacers to pre-compress the springs. The next problem was how to actually compress the springs enough to get the clip in. I have 2 three jawed pullers, one was way too small and the second was just a tad too big (it was an irresistible auction purchase years ago and I have never used it)
I was just about to make something out of timber and threaded rod when I remembered by bearing separator set. The photo shows it in use.
What happened next was sheer stupidity on my part. As I had not put fork oil in first I needed to pour some in through the fillers in the top plug. What a shame I had made myself up a set of solid alloy spacers...
The bearing separator got a second work out and to guard against future stupidity I drilled a 10mm hole through the spacers.
Then it was time to do the shockies.
First problem was that the Spaniards had made the loops and bushes too long to fit in frame mounts. Time was wasted driving the bushes out and then driving the steel bushes out of the rubbers so that I could grind them down about 1.5mm.
Finally, after taking nearly all day the forks were back together and the shocks were in. The acid test of me hoping onto the bike and measuring static drop reveals that sometime soon I need to make up new 1" spacers of the forks, but hey, they are much better than they were.
To my utter amazement the Spaniards actually fitted the springs i asked for and it required only the second from the bottom pre-tension position to get the 1" static drop I was looking for.
Today, in spite of the threat of rain I was going riding - the front end is much, much better than it was, no longer bottoming out over minor bumps, but I do need to dump the fluid and try again. With a full compliment of damper rod rings 100% 10w Castrol fork fluid is way too heavy, next weekend I'll go 100% 5 weight and see how light it is and then hopefully the third blend of 5w & 10w will be on the money.
The Betors are no the greatest shock on the planet, but they are rebuildable and given that the spring rate is close to perfect I need to fiddle with fluid weight and level to get the damping closer to what I want.
I intend to drill a hole as near to the bottom as I can and then have a nut welded over the hole, I can then use a grub screw as a means of both draining the existing fluid and putting new fluid in. or i might just lose interest and fit a set of Ikons like I probably should have at the get-go.
Lastly, proof that it really is back in one piece, with its nice shiny new Betors.
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The best laid plans.......
Pulling the forks apart I managed to lose one of the circlips on the bottom of the fork. I am usually extremely careful of such things, but the dog chose that precise moment to give me a "hello boss" tongue in the ear which caused me to lose concentration. The clip hit the floor and bounced, I listened carefully for the landing so I'd have a rough idea where to start looking, but I didn't hear it. The workshop/carport can be a very big area when you are searching it on your hands and knees ....
It'll turn up
I foolishly did my first spline lube out side in the garden and the little circlip that secures the pivot pin on clutch operating arm launched itself into the nearest flower bed. There was little chance of finding it but I did look before making a temporary new one and riding into town in search of something closer to the correct item. 6 months later when raking out the flower bed what should turn up but the original circlip and it wasn't even rusty. I know I should fit a bolt and nut but the original pin is such a beautifully precise fit that I prefer that over a sloppy bolt.
I like the idea of shocks that you can change the oil in.
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"I like the idea of shocks that you can change the oil in."
You should buy a set of Fournales shocks. ( http://www.fournales.fr ).
They are built like hydraulic jacks as in aviation work. So the spring is made of air and the oil is here "only" to dampen the oscillations.
You can adjust the pressure to cope with various load and/or riding style. And you can change the oil yourself.
As per longevity, I've a set on my R65 I bought in 1987 and they are still going strong, 160 000 km after. Last but not least, you can buy the gaskets to repair them if the need arise.
A once in a lifetime buy...
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The best laid plans.......
Along this same thought line, I have found that no good deed goes unpunished. ;)
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I have been known to drag a super magnet in cloth around the flow to pickup lost things.
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My worst case of "sprung parts" was when I was putting a timing chain in an R60. It was one of the new style chains with two small, oddly sized (as in you can only get them with the chain) e-clips instead of one big fish-clip to hold the master link on.
Maneuverable space was at a minimum when I let one of the tiny e-clips go flying off sideways as I was laying on my back on the garage floor. Fortunately I had spilled some oil earlier and therefore heard the tiny little e-clip land in the pile of kitty litter I was using to soak up the puddle. I've been extra cautious ever since then. The saying around here is "it takes ten 'atta boys' to make up for one 'oh shit'"
When I build my dream garage I'll be looking into magnetic floor paint!