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Author Topic: Winter project underway  (Read 9756 times)

AlfromNH

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Winter project underway
« on: September 27, 2013, 02:55:42 PM »
I posted my introduction in the Chit Chat forum. I've now started disassembly of my '79 R65.

So far, no big surprises. The front wheel bearings feel real good, but the steering head bearings are notchy and stiff.

I noticed both forks have bosses for calipers. Here's the right leg:


And the brake line from the master cylinder feeds into this block, which has a second outlet plugged:


Is all this standard for a '79? And would it be as simple as bolting on a 2nd disc using the same bolt pattern, then adding a caliper and brake line?

Offline nhmaf

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Re: Winter project underway
« Reply #1 on: September 27, 2013, 04:40:10 PM »
Not all the standard R65 bikes came with the fork lowers for the right side disc brake, but many of the north american bikes did - like yours!  This is a bonus, as it can be tricky to find a right side fork slider with the mounting lugs if you don't have one.    Basically, you do need the rotor, rotor carrier that bolts to wheel hub, calipers, some top-hat shaped spacers inserts that slide into those lug holes, and brake line to go to that splitter.

Depending on the size of your master cylinder (size in mm is stamped on body of the metal base, sometimes on the bottom) you may or may not need to change that out.  The 79 bikes had a round plastic reservoir m/c that was either 14mm or 16mm piston diameter (depending on whether setup for single or dual front discs).  The later models had rectangular m/c assembly that is still currently available (new parts from dealer, and rebuild kits) while the old round style are only available on the used market and they are not technically rebuildable, though some have managed in some cases..   The later rectangular units came in 13mm and 15mm, again, for single or dual disc setup, but some people prefer running the smaller m/c with the dual disc setup as it gives them more lever travel and is easier to modulate.   With 15mm m/c on my LS with dual discs I cannot squeeze the lever anywhere near to the handlebar with normal 1 handed grip, and the front wheel is easily locked up with only 2-3 fingers.  Some prefer less rapid progression.
Recommend you pitch the old rubber brake line and get some new stainless steel braided lines - you can order premade sets from bobs BMW in Maryland, they have someone build them to order.   Or you can get the OEM BMW lines, but the SS lines definitely seem to offer a bit more "bite".
« Last Edit: September 27, 2013, 04:41:08 PM by nhmaf »
Airhead #12178 ? BMWMOA #123173 ?BMWRA #33525 ?GSBMWR #563 ?1982 BMW R65LS ?1978 BMW R100/7 1998 Kawasaki Concours

AlfromNH

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Re: Winter project underway
« Reply #2 on: September 27, 2013, 07:44:49 PM »
Quote
Not all the standard R65 bikes came with the fork lowers for the right side disc brake, but many of the north american bikes did

Interesting. I don't know that I'll add a 2nd disc, maybe down the road sometime. That "splitter" block is standard too? I guess it is the means for connecting the brake light switch, even if the second output is not needed.

The brake lever had no response, the master cylinder(the round type) was basically empty. So I'm gonna replace the lines, and rebuild both the mc and the caliper. Actually, I was planning on rbuilding the mc, but that's not an option?  ::)

Offline wilcom

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Re: Winter project underway
« Reply #3 on: September 28, 2013, 10:06:22 PM »
Quote
, I was planning on rbuilding the mc, but that's not an option?Roll Eyes

I rebuilt the round 16mm on my 79 with parts from Rubber Chicken Racing in PA. No problem encountered.
Joe Wilkerson
Telephone man with a splash of Data
Menifee, CA

Present:
1984 BMW R65LS "Herr Head"
past:
1982 BMW R65LS
1979 R65
1980 R65
1982 R80RT
1974 R90/6
1972 R75
1964 R50/2
19xx R27
ZX-11

Armen

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Re: Winter project underway
« Reply #4 on: September 29, 2013, 09:59:05 PM »
Unless you are trying to make it original, consider this route:
Use a later model 12mm master with a mechanical brake light switch located at the lever.
Ditch the multi-piece brake line/splitter mess and go with a single stainless braided brake line.
Simpler, cleaner, better hydraulic ratio.
-Armen

AlfromNH

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Re: Winter project underway
« Reply #5 on: September 30, 2013, 07:04:41 AM »
Quote
Unless you are trying to make it original, consider this route:
Use a later model 12mm master

I like this idea, but the lever assy has the mc, throttle, and switches all integrated. Is there a 12mm mc that will bolt right on?


BTW, my mc is indeed a 13mm:

Offline steve hawkins

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Re: Winter project underway
« Reply #6 on: September 30, 2013, 09:27:53 AM »
Yes it will.  or at least it will with a bit of 'fettling'.

I am running just such a configuration on my 79 R65.  A 79 twin pull throttle, a post 81 'square' master cylinder for one disc, and a single braided stainless pipe. I am using banjo fittings also.  I ditch all the rest of it.

I would add that it used to have 2 disc brakes but have gone to one.  I tend to run my bike light.

The 'fettling' I alluded to, I think concerns the bolting up of the master cylinder to the throttle mechanism - a little bit of work with a round file, or a drill to get the holes to line up for the bolts if I recall.

Works a treat.  I prefer the twin pull throttle of the earlier model and was glad to be able to keep it.

Cheers
Steve Hawkins R100 (that wants to be an R65)

AlfromNH

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Re: Winter project underway
« Reply #7 on: September 30, 2013, 04:59:01 PM »
Quote
Yes it will.  or at least it will with a bit of 'fettling'.

I am running just such a configuration on my 79 R65.  A 79 twin pull throttle, a post 81 'square' master cylinder for one disc, and a single braided stainless pipe.

Excellent info, thanks! It's off an '81 R65? Is there a range of models years that are the same unit? Off to eBay...

Offline steve hawkins

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Re: Winter project underway
« Reply #8 on: October 01, 2013, 04:00:22 AM »
You just have to be careful of the master cylinder size - i.e. its for running an single disc, not two.

The same style of master cylinder was used across the range, I have a similar one fitted to my 82 R100 but is of a larger bore.

I am not sure how long this style of master cylinder was used for, it could be for as long as the airheads were in production - i.e. after the monolevers.  I would not be surprised if the same style was used on the Ks as well.  As they had Brembo's.  

But remember you have a single ATE caliper so the feel will be slightly different as the ATE caliper has a different piston size to a Brembo unless you can get an exact match.  But you should get away with it.

Rev. light
« Last Edit: October 01, 2013, 04:03:01 AM by steve_hawkins »
Steve Hawkins R100 (that wants to be an R65)

Offline marcmax

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Re: Winter project underway
« Reply #9 on: October 01, 2013, 09:37:56 PM »
I have wondered from the first day I bought my R65LS if I could move my brake light switch to the splitter and get it off of the handlebars. Now I know.
Keep your bike in good repair: motorcycle boots are not comfortable for walking.

1982 R65ls    1984 R65ls

Offline Rob Valdez 79 R65

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Re: Winter project underway
« Reply #10 on: October 03, 2013, 03:09:18 AM »
Quote
I have wondered from the first day I bought my R65LS if I could move my brake light switch to the splitter and get it off of the handlebars. Now I know.
Or eliminate it and make sure you use you rear brake all the time.

I like the hydraulic switch fitted to the early models.  I only had to replace mine once in 35 years, due to getting gummed up with old brake fluid.  

I thought all R65's came with bosses on the right hand fork slider.  I think BMW was thinking they could sell a lot of add-on kits?

It is the 70's model Type 247s that can be difficult to source a right hand leg with bosses.

AlfromNH

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Re: Winter project underway
« Reply #11 on: November 06, 2013, 08:18:19 AM »
I'm being redundant here, as I posted this pic in another thread, but I know how much we all like pictures!  8-)

This is my bike as it sits now


The only reassembly I've done so far is the steering head, with new bearings and cleaned up triple clamps.

My fork internals were a mess. I bought a set of forks off eBay, and they only need a few parts which I have on order. Once I rebuild and reinstall the forks, I'm going to roll it out to the garage and pull the motor.

I'm contemplating have the frame powdercoated. There's a local place that will strip and powdercoat for ~$300. The frame's not terrible, just spots of rust except under the battery tray which is quite nasty.

I like the idea of a freshly treated frame, altho I don't intend to go nuts making the bike look showroom new. So I'm undecided about that at the moment.

Offline montmil

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Re: Winter project underway
« Reply #12 on: November 06, 2013, 08:50:25 AM »
Once the engine is out and the chassis is more accessible, take a good look at your centerstand. In your photo, the stand appears to be too far over-center; indicating excessive wear on the stand and/or the chassis stops.

I bit of welding build-up and grinding will make lifting the bike off the stand much easier.
Monte Miller
Denton, TEXAS
1978 BMW R100S
1981 BMW R65
1983 BMW R65
1995 Triumph Trophy
1986 VW Cabriolet

AlfromNH

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Re: Winter project underway
« Reply #13 on: November 06, 2013, 01:13:46 PM »
Good eye, Monte. The centerstand definitely needs help. And the hole in the frame tab for the sidestand is ovalled also. I'll look into putting a bushing in there.

Offline steve hawkins

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Re: Winter project underway
« Reply #14 on: November 07, 2013, 02:18:20 PM »
If you can find the cash, I would replace the side stand with a surefoot.

If its had a lot of use it could fail.  Don't ask me how I know ;)

Inspect it carefully before refitting

Cheers

Steve H
Steve Hawkins R100 (that wants to be an R65)