'81 R65 carb, head, cylinder and exhaust work

[ShutterPilot]

So, this isn't exactly a full restore deal, but I've rebuilt the dual ate brakes, and pulled the heads and cylinders for a good cleaning and some machine work on the valves, guides and seats.
I also (finally) got the headers off, and have new X-overs on order, so those will soon look all new and spiffy.
Here's a photo of the bits layed out on the bench before I do the install - my own little "altar to the gods of speed" as it were...

Thank you so much to all of you who have offered help and ideas over the months as I've gotten my feet wet. Now? I just gotta get it all back together. Cinch, right?

[ShutterPilot]

Detail of the heads - Bombar's Beemers in Durham, NC did a great job, I think, of getting them sorted out.
Of course, now the rest of the engine will look downright grimy in comparison...

[arvo92]

My god how clean and sexy these cylinders look. After seeing these pictures I think my old lady should get a backrub as well...

[steve hawkins]

Yes, it is not desperately difficult.  But it is always better with a mate to talk to if you have never done it before, even if he/she has little experience with the R65.

Its good to bounce ideas around and discuss areas of 'interpretation' in the manuals.

If not, we'll be yer mates, it will just take us a little longer to respond.

Looking forward to seeing it go together.  

As Monte says: "No pictures - It did not happen"

Cheers

Rev Light

[Tony Smith]

I see that your heads have the "clean air" sub-ports. Are you intending to refit the system or blank it off at the heads?
 
The reason I ask is that I have just bought a set of R80 heads to re-condition as part of a somewhat overdue refresh for my wife's bike. I know that the threads are 16*1mm but have been unable to find a cap in that size. I am hoping you can send me in the right direction as presently the only thing I can come up with is to buy 1681mm couplings and weld them up which (considering my welding ability) will not be pretty.

[montmil]

Tony, the cylinder head ports for that silly California Pulse Air System can be plugged with BMW oil drain plugs that have the Allen wrench drive. I'm presently away from my shop but Snowbum has a tech article listing the BMW parts. Makes a tidy job of it. BTW, the timing port window's rubber plug fits the airbox holes formerly occupied by the piping.

[marcmax]

Boxercafe has put together a package of all the bits needed to block of heads, carbs and holes on airbox. About halfway down the page.

http://www.boxercafe.com/startercover.htm

[ShutterPilot]

As I'm racing in a 100% stock class, I needed to keep the air system intact. Indeed, I purposely was seeking a 100% stock bike for this project, not easy for a bike going on 34 yrs old and prone to easy updates and mods to improve it.
Here's a photo after I completed the reassembly over the weekend - 100% stock as she was in October of 1980:

[Tony Smith]

Tony, the cylinder head ports for that silly California Pulse Air System can be plugged with BMW oil drain plugs that have the Allen wrench drive. I'm presently away from my shop but Snowbum has a tech article listing the BMW parts. Makes a tidy job of it. BTW, the timing port window's rubber plug fits the airbox holes formerly occupied by the piping.

What has me a but nervous is getting the original fittings out of the heads. I am in the process of doing a "double swap". I've bought a pair of R80 heads from the USa (hence the clean air ports) I am going to have those done up and they will then go on the wife's R65/80 as part of its long overdue top end freshen up.