Author Topic: R65 Resurrection  (Read 23877 times)

Offline mrclubike

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Re: R65 Resurrection
« Reply #30 on: October 02, 2018, 09:00:27 PM »
I think I wold try to go towards a repair Like Justin suggested
See if you can drill the original plug out big enough to allow it to be used as a thread repair insert and just JB weld it in
You may be able to drill   it  out enough to get a 8mm bolt in it

Darn Helciols can be tricky
1982 R65 running tubeless Snowflakes
2004 R1150R

Offline Tony Smith

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  • Graduate, Wallace and Gromit School of Engineering
Re: R65 Resurrection
« Reply #31 on: October 03, 2018, 03:21:02 AM »
Quote

Darn Helciols can be tricky

If I were to even try to do this I'd use a cut down tinesert rather than a helicoil.

1978 R100RS| 1981 R100RS (JPS) | 1984 R65 | 1992 KLE500 | 2002 R1150GSA |

Offline Barry

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Re: R65 Resurrection
« Reply #32 on: October 03, 2018, 06:28:02 AM »
Justins repair was very neat. You are only going to be putting a maximum of 150 cc of oil in so it doesn't need a big fill hole.
Barry Cheshire, England 79 R45

Offline TomHoldom

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Re: R65 Resurrection
« Reply #33 on: October 03, 2018, 06:59:55 AM »
Hi Tony,
I think I'll go down your 'temporary' rubber bung solution for the time being. Just trying to source the right one - do you think a tapered rubber bung 9mm diam and 11,5mm diam x 20mm ht would be about right?
I'll add Justin's or the Helicoil solutions to my phase 2 list.....

For cleaning up the calipers, do I use break fluid and an old toothbrush?

Offline tunnelrider

  • Posts: 321
Re: R65 Resurrection
« Reply #34 on: October 08, 2018, 01:05:42 AM »
Just adding a post to bring this topic back to the current board as it was before I deleted a post I made, to start a new topic.  Somehow Tom's R65 resurrection topic disappeared off the board too.
« Last Edit: October 08, 2018, 01:08:14 AM by tunnelrider »
'85 Black R65 / '74 GT185 / '83 Pantah 500 / '90 Super Tenere 750  / '01 DRZ400 dirt only

Offline Tony Smith

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  • Graduate, Wallace and Gromit School of Engineering
Re: R65 Resurrection
« Reply #35 on: October 08, 2018, 02:12:38 AM »
Quote
Hi Tony,
 do you think a tapered rubber bung 9mm diam and 11,5mm diam x 20mm ht would be about right?


For cleaning up the calipers, do I use break fluid and an old toothbrush?

If the bung fits tightly whilst still leaving enough material on top for you to grab when you need to remove it, it will be golden.

I've attached a photo of the "bung" in the final driveon the wife's R65/80, ignore the oil weep marks, I am going to rebuild it this week, for some reason I've had to do 3 final drive rebuilds this year, which is more than I've had to do in the previous 40 years of Airhead onwership. The only thing I'll say is that I am now a dab hand at getting the little bastard of a bearing out that carries the "nose" of the pinion shaft, I've borrowed from the old mechanic's cookbook for removing the clutch bearign or bush from the centre of a flywheel - turn up a piece of steel that just fits inside the bush/bearing and then pack as much grease as possible into the bush/bearing. Insert turned steel drift and then smack the end of it smartly with a big hammer, the grease, having nowhere to go, forces the bush/bearing out.

As to cleaning the caliper - whatever floats your boat, just be sure that when to put it back together that you only use clean brake fluid as assembley lube.

1978 R100RS| 1981 R100RS (JPS) | 1984 R65 | 1992 KLE500 | 2002 R1150GSA |

Offline TomHoldom

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Re: R65 Resurrection
« Reply #36 on: October 08, 2018, 05:58:47 AM »
thanks Tony

Offline DadsR65

  • Posts: 30
Re: R65 Resurrection
« Reply #37 on: October 11, 2018, 05:31:41 AM »
Quote
Hello again



STRIPPED DRIVE SHAFT FILL
Barry, I've looked at the heliocoil kits - much simpler than I first imagined. Do you know which thread I need - looks like M12, but there is M12 x 1,5 x 16,3 kit or M12 x 1,25 x 16,3 see photo below; do you know which one of these might do the job?
Presumably I'll need to remove the rear suspension spring for access?

Tom

I did this repair.  Here's the final result:  https://advrider.com/f/threads/new-airhead-project.1260761/page-3#post-33742346

Read up a bit in the thread to see how I did it.  No leaks to date.

Offline TomHoldom

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Re: R65 Resurrection
« Reply #38 on: October 16, 2018, 10:34:13 AM »
just got my other front disk brake pads out, and this set also have a decent amount of pad left, though a bit more rust/flakey paint on the rear side - is this something to worry about, or can I re-use.
If I need to replace, how can find the correct replacements for 36mm Brembo Calipers?
see photos
« Last Edit: November 05, 2020, 02:22:45 PM by Justin B. »

Offline TomHoldom

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Re: R65 Resurrection
« Reply #39 on: October 16, 2018, 10:43:58 AM »
Tyres:
should I also assume that tyres have to be changed
see photos
I see these are suggested as a not to pricey option

Rear Tyre
Metzeler ME77 - CLASSIC 
SIZE: 4.00 -18 64H

Front Tyre
Metzeler ME22 - CLASSIC 
SIZE: 3.25-18 59P reinf.

any advice appreciated on these
(my usage will be occasional mainly taking it easy around country lanes)
« Last Edit: November 05, 2020, 02:24:08 PM by Justin B. »

Offline Barry

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Re: R65 Resurrection
« Reply #40 on: October 16, 2018, 01:38:54 PM »
Nothing wrong with the original quality of those tires but how old are they ?    You should be able to work it out from the date codes on the side wall.
Barry Cheshire, England 79 R45

Offline Barry

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Re: R65 Resurrection
« Reply #41 on: October 16, 2018, 01:42:42 PM »
Quote
just got my other front disk brake pads out, and this set also have a decent amount of pad left, though a bit more rust/flakey paint on the rear side - is this something to worry about, or can I re-use.

In terms of wear those pads are nearly new so I would be inclined to clean them up and repaint the backs.
« Last Edit: October 16, 2018, 01:43:07 PM by bhodgson »
Barry Cheshire, England 79 R45

Offline MrTall100

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Re: R65 Resurrection
« Reply #42 on: October 19, 2018, 01:41:05 PM »
Hi,

Might not be of help now but although really really expensive the 16mm master cylinder from Motorworks fits the lever assembly on a 78-80 R65 which has the round reservoir.

I bought a ‘reconditioned’ lever and master cylinder assembly on eBay, only to find it leaked straight away which meant I had little options  :'(

Andrew

Offline MrTall100

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Re: R65 Resurrection
« Reply #43 on: October 19, 2018, 01:42:08 PM »
Sorry mean’t to say twin disc although they sell other sizes.

Offline Tony Smith

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  • Graduate, Wallace and Gromit School of Engineering
Re: R65 Resurrection
« Reply #44 on: October 19, 2018, 04:03:47 PM »
My GOD!
The only time an R65 would need a 16mm master cylinder is if you were fitting Brembo 4-spot calipers.

I did the math when I was considering doing just that, BMW use a 17mm or 19mm for those calipers depending on whether you have a K100, K1100 or R1100/1150 and the consensus is that they can be just a little wooden.

I worked out that 16mm gave a nice ratio and 15mm  would be OK once the hand learned moderation.

16mm with Brembo F08s would require horrendous lever pressure in order to work, 13mm is about right for most people, I am currently running twin K100 sourced Brembo 2-spots o a 12mm master cylinder and whilst I'll admit it took a ride or two for the hand to learn moderation, I am now completely happy with it (moderation required because 1 finger can lock the front wheel without raising a sweat)
1978 R100RS| 1981 R100RS (JPS) | 1984 R65 | 1992 KLE500 | 2002 R1150GSA |