1989 BMW R100GS-Paris Dakar Restoration
- Thread starter Paul Rochdale
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Paul Rochdale
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Turkish
In all fairness, I was really just an 'assembler' with the real work carried out by Jim Cray, the powder coaters, Chris Tunbridge and Hagons. It's really a bit like Lego, and by just taking things one stage at a time, and picking up tips from the helpful souls on here, it slowly came together. It could have been completed in a far shorter time but I was in no rush and actually liked cleaning and polishing bits and bobs. I kick myself for not being proficient at doing the timing and adjusting the carbs but I'm far better at learning from watching others do stuff, rather than trying to follow the written word.
I shall take her for a test ride once this heavy rainfall stops and book her in for an MoT next week if all goes well. After six years of dry storage I fancy taking her for a bit of a trip, probably to my favourite Motorcycle Loft Motel near Ostend (again).
Patience? An awful lot of swear words were drowned by the workshop radio. Workshop? A £700 purchase on eBay but an awful lot on the foundations, blockwork and concrete floor.
Sorry those images ar 90 degrees out. Oh well, it would my head too much to alter them.
In all fairness, I was really just an 'assembler' with the real work carried out by Jim Cray, the powder coaters, Chris Tunbridge and Hagons. It's really a bit like Lego, and by just taking things one stage at a time, and picking up tips from the helpful souls on here, it slowly came together. It could have been completed in a far shorter time but I was in no rush and actually liked cleaning and polishing bits and bobs. I kick myself for not being proficient at doing the timing and adjusting the carbs but I'm far better at learning from watching others do stuff, rather than trying to follow the written word.
I shall take her for a test ride once this heavy rainfall stops and book her in for an MoT next week if all goes well. After six years of dry storage I fancy taking her for a bit of a trip, probably to my favourite Motorcycle Loft Motel near Ostend (again).
Patience? An awful lot of swear words were drowned by the workshop radio. Workshop? A £700 purchase on eBay but an awful lot on the foundations, blockwork and concrete floor.
Sorry those images ar 90 degrees out. Oh well, it would my head too much to alter them.
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Paul Rochdale
Registered user
Ah, that's better.
Paul Rochdale
Registered user
Ah, small glitch. I replaced the standard GS handlebars with some slightly lower Renthal-type ones, and the inner ends of the handlebar 'guards' clout the dash panel. So I shall fit some handlebar risers. The ones Migsel has on his webiste seem to fit the bill - 35mm raise for 22mm dia. bars. Any alternatives?
Paul Rochdale
Registered user
Too late. I've ordered Migsel's.
Paul Rochdale
Registered user
Right, handlebar risers fitted, steering lock improved, so took her on a half mile ride to Chris Tunbridge's. Bike lumpy as hell, carb adjustments not right. First ride for me in fourteen months, for the bike in six years. Got her home without incident and booked her in for an MoT 1015hrs tomorrow morning. 
She needs fresh petrol instead of lawnmower fuel, and a visit to Jim Cray to tweak her a bit.
She needs fresh petrol instead of lawnmower fuel, and a visit to Jim Cray to tweak her a bit.
Paul Rochdale
Registered user
Well she passed, if not with flying colours at least with lots of admiring comments from the mechanics. The crappy rear brake registered a mighty 19% on the clapometer although the front was fine. They were sympathetic to a bike which is 24 years old, as they were with the brake lever which failed to operate the brake light. No emissions test nor head light alignment check: perhaps old bikes don't need them? The headstock bearings had settled by the time I returned home and need tweaking and the carb lumpiness is always there below 40mph. Above that, she flies. Dead comfy with her USA single seat and her old tyres gripped the damp roads pretty well. It was smashing to ride her again after fourteen months away from the saddle, and the six years since I last had her on the road.
I have read somewhere that the rear brake linings can be replaced with those from a milk float, I kid you not, which are softer and grip far far better. The brake is properly adjusted - I even did the Simon McCarthy mod of altering the angle of the pull- there must be a way to a better brake.
I have since been in touch with Ian Campbell of Classic Brake Services in Derbyshire, one of the tiny number of craftsmen around capable of getting old drum brakes to work by using grippier, more modern materials. Let's see what his reply brings.
I have read somewhere that the rear brake linings can be replaced with those from a milk float, I kid you not, which are softer and grip far far better. The brake is properly adjusted - I even did the Simon McCarthy mod of altering the angle of the pull- there must be a way to a better brake.
I have since been in touch with Ian Campbell of Classic Brake Services in Derbyshire, one of the tiny number of craftsmen around capable of getting old drum brakes to work by using grippier, more modern materials. Let's see what his reply brings.
Paul Rochdale
Registered user
http://www.youtube.com/watch?v=GAp_w6QAK08
Well she passed her MoT on Thursday after a six year dry storage, a nine month restoration and a fourteen month riding lay-off for me. Not everything is hunky dory. The steering head bearings had settled during the first ride and these I've adjusted. Also she's as lumpy as hell below 40mph so I am booking her in with Jim Cray (who rebuilt the engine) next week for some final tweaking. Dead chuffed though. I am now thinking of a long weeked bimble across to Belgium in the next few weeks before the winter closes in.
Thanks to Chris (Tunbridge) for the video which briefly shows his workshop where he performs his magic with a spray gun. Chris also spent a few hours, some weeks ago, replacing the troublesome original bullet connectors under the tank (as no amount of cleaning could get them completely free from corrosion) with brand new bullets and shrink wrapped joints. Another of his skills.
One strange side effect from only an hour's riding. My hip joints are painful, something I've not noticed before, four or five hours AFTER riding. Yet I find the GS supremely comfortable. Strange.
Well she passed her MoT on Thursday after a six year dry storage, a nine month restoration and a fourteen month riding lay-off for me. Not everything is hunky dory. The steering head bearings had settled during the first ride and these I've adjusted. Also she's as lumpy as hell below 40mph so I am booking her in with Jim Cray (who rebuilt the engine) next week for some final tweaking. Dead chuffed though. I am now thinking of a long weeked bimble across to Belgium in the next few weeks before the winter closes in.
Thanks to Chris (Tunbridge) for the video which briefly shows his workshop where he performs his magic with a spray gun. Chris also spent a few hours, some weeks ago, replacing the troublesome original bullet connectors under the tank (as no amount of cleaning could get them completely free from corrosion) with brand new bullets and shrink wrapped joints. Another of his skills.
One strange side effect from only an hour's riding. My hip joints are painful, something I've not noticed before, four or five hours AFTER riding. Yet I find the GS supremely comfortable. Strange.
Paul Rochdale
Registered user
Right, I have just returned from my first trip on the bike since her restoration. As everything inside the engine has been replaced, I thought I would stick to the BMW original running in instructions, 500 miles up to 60-65mph followed by 500 miles up to 70mph. I decided on a few days in Belgium and Holland staying at Ghent and Bruges with a visit to the 11am Menin Gate ceremony yesterday morning. And with almost no motorway riding if I could help it.
I took the bike over to Jim Cray last week for final tuning - the timing was way out and he discovered a few little things like on one carb, the alloy choke stops had snapped off. Also the rubber boot at the bottom of the speedo cable had perished and as he warned me of rainwater entering the gearbox at that point, I fitted a new boot and cable tied it in place.
I caught the 0825hr P&O sailing from Dover on a sunny Friday morning along with hundreds of noisy school kids and rode to Ghent along the minor roads past Cassel and Popperinge. Excellent road, and very quiet. After a couple of days exploring this beautiful and friendly medieval city, I rode north into Holland to Terneuzen then headed west to Sluis.The weather went from sunshine to sleet with a biting wind. I headed on to Bruges and my hotel (Hotel Albert I, opposite the bus station). After a stroll around the town my some of my favourite bars have become restaurants, I went to my favourite of all, Bertie's Bar (400 beers). On Monday I rode to Ieper and arrived at the Menin Gate ceremony - very moving with thousands of people, a wonderful choir and a band. Although I stood up against the side of the gate, I didn't realise Phil the Greek had also come. Then it was off to Calais and an early boat. This ship was almost deserted as a crewman and I securely tied the bike down. Everything went so well until that one big isolated wave in mid-Channel. There was this almighty bang as if the ship had hit a rock and everything shook violently. Returning to the car deck, I found the Secdem screen smashed in three pieces with my helmet and gloves lying nearby. That almighty bang had caused the bike to fall to the right and it seems the handlebars crashed onto full lock and broke the screen. Everybody was very apologetic and the First Officer came down to write out a damage report, itemising every mark and scratch he could find. But I was amazed that very little damage had been caused.
Never mind. I must find a way of actually hearing the instructions given by my onboard GPS - impossible with earplugs.
So how was the bike? Well she went like a turbine, quite unlike what I remembered when I had last ridden her six years ago. At 100 lbs lighter than my departed Pan European, I found her light and nimble to ride around city centres (wet cobbles and tramlines) and nice and smooth out on the open road. I was surprised at what effect that small screen had as riding hime from Dover with no screen put a lot of wind on my helmet with it trying to lift off. I filled the tank up at 250 miles although she hadn't gone on to reserve at that point. I have no idea as to her range - 275 miles perhaps? It was a nice surprise to be able to get both feet on the ground, and at a squeeze, both heels, the first time in years.
Home in time to get changed and go to our grand-daughter's birthday party but I was whacked so left early for some quiet time at home in front of the fire.
This morning I am looking into what screen to buy. Another Secdem perhaps? My Pan had an MRA Vario which was brilliant and it seems there is one for the PD too.
I took the bike over to Jim Cray last week for final tuning - the timing was way out and he discovered a few little things like on one carb, the alloy choke stops had snapped off. Also the rubber boot at the bottom of the speedo cable had perished and as he warned me of rainwater entering the gearbox at that point, I fitted a new boot and cable tied it in place.
I caught the 0825hr P&O sailing from Dover on a sunny Friday morning along with hundreds of noisy school kids and rode to Ghent along the minor roads past Cassel and Popperinge. Excellent road, and very quiet. After a couple of days exploring this beautiful and friendly medieval city, I rode north into Holland to Terneuzen then headed west to Sluis.The weather went from sunshine to sleet with a biting wind. I headed on to Bruges and my hotel (Hotel Albert I, opposite the bus station). After a stroll around the town my some of my favourite bars have become restaurants, I went to my favourite of all, Bertie's Bar (400 beers). On Monday I rode to Ieper and arrived at the Menin Gate ceremony - very moving with thousands of people, a wonderful choir and a band. Although I stood up against the side of the gate, I didn't realise Phil the Greek had also come. Then it was off to Calais and an early boat. This ship was almost deserted as a crewman and I securely tied the bike down. Everything went so well until that one big isolated wave in mid-Channel. There was this almighty bang as if the ship had hit a rock and everything shook violently. Returning to the car deck, I found the Secdem screen smashed in three pieces with my helmet and gloves lying nearby. That almighty bang had caused the bike to fall to the right and it seems the handlebars crashed onto full lock and broke the screen. Everybody was very apologetic and the First Officer came down to write out a damage report, itemising every mark and scratch he could find. But I was amazed that very little damage had been caused.
Never mind. I must find a way of actually hearing the instructions given by my onboard GPS - impossible with earplugs.
So how was the bike? Well she went like a turbine, quite unlike what I remembered when I had last ridden her six years ago. At 100 lbs lighter than my departed Pan European, I found her light and nimble to ride around city centres (wet cobbles and tramlines) and nice and smooth out on the open road. I was surprised at what effect that small screen had as riding hime from Dover with no screen put a lot of wind on my helmet with it trying to lift off. I filled the tank up at 250 miles although she hadn't gone on to reserve at that point. I have no idea as to her range - 275 miles perhaps? It was a nice surprise to be able to get both feet on the ground, and at a squeeze, both heels, the first time in years.
Home in time to get changed and go to our grand-daughter's birthday party but I was whacked so left early for some quiet time at home in front of the fire.
This morning I am looking into what screen to buy. Another Secdem perhaps? My Pan had an MRA Vario which was brilliant and it seems there is one for the PD too.
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Bugger, lost £5 in the UKGSer sweep that your front calliper would play up ! 
Good write up on the project
Good write up on the project
Paul Rochdale
Registered user
Turkish
Well there was no cause to get worked up as I fully expected lots of damage. The signs close to the bike parking area clearly stated, as they have done for a couple of years now on P&O ferries, that it's the rider's responsibility to secure the bike. The deckhand helping me, whose name was noted by the First Officer, actually helped me again as he could confirm the bike had been properly secured. I intend to slightly shorten the homemade sidestand as she's a tad too vertical and only really steady on a slight camber or a perfectly flat surface.
Kenny
I was quite delighted with the replacement four-pot Brembo caliper after I'd stupidly buggered up the old one and it works pretty well, although I braked in plenty of time as the roads and cobbles were wet all weekend. Even the rear brake works (mostly) after Jim Cray tweaked it a little (I had modded the end to get a straighter pull on the cable and it touched the frame). I am dead chuffed with the bike.
Ever ridden on wet cobbles with tramlines?
Well there was no cause to get worked up as I fully expected lots of damage. The signs close to the bike parking area clearly stated, as they have done for a couple of years now on P&O ferries, that it's the rider's responsibility to secure the bike. The deckhand helping me, whose name was noted by the First Officer, actually helped me again as he could confirm the bike had been properly secured. I intend to slightly shorten the homemade sidestand as she's a tad too vertical and only really steady on a slight camber or a perfectly flat surface.
Kenny
I was quite delighted with the replacement four-pot Brembo caliper after I'd stupidly buggered up the old one and it works pretty well, although I braked in plenty of time as the roads and cobbles were wet all weekend. Even the rear brake works (mostly) after Jim Cray tweaked it a little (I had modded the end to get a straighter pull on the cable and it touched the frame). I am dead chuffed with the bike.
Ever ridden on wet cobbles with tramlines?
Range
I usually get 320 to 330 miles before going to reserve but the engine has been tweaked!
I usually get 320 to 330 miles before going to reserve but the engine has been tweaked!
Paul Rochdale
Registered user
Hmm, As I was giving the bike a good wash this morning after the very wet last few days, a couple of things I noticed -
1. The chrome-like finish to the alloy rims was covered with surface corrosion (after only three days?).
2. With the lights on, the rear brake light is on. I know the front brake light switch doesn't work and I've adjusted the Mickey Mouse-rear brake pedal switch a few times, but it seems the lightest touch and it goes out of adjustment. More tinkering tomorrow.
3. Judging by the rust, the EBC Pro-Lite floating disc must be cast iron.
4. The alloy sump guard makes a very good muck collector.
5. The rebuilt wheels (Hagon) have quite loose spokes particularly the front wheel. I must give them a call.
1. The chrome-like finish to the alloy rims was covered with surface corrosion (after only three days?).
2. With the lights on, the rear brake light is on. I know the front brake light switch doesn't work and I've adjusted the Mickey Mouse-rear brake pedal switch a few times, but it seems the lightest touch and it goes out of adjustment. More tinkering tomorrow.
3. Judging by the rust, the EBC Pro-Lite floating disc must be cast iron.
4. The alloy sump guard makes a very good muck collector.
5. The rebuilt wheels (Hagon) have quite loose spokes particularly the front wheel. I must give them a call.
I use 'Speaker-plugs' - earplugs with speakers inside. They are excellent.
I have my Zumo 660 wired to a Starcom Digital box which handles all the comms (passenger, bike-to-bike radio, mobile phone, Sat Nav). There is a double socket at the side of my helmet into which the connector cable and speaker plugs are connected. The speaker-plug plug cuts out the speakers in the helmet, so if I don't use them I still have the helmet speakers.
Not cheap (at all
) but works well.It is possible to connect speakers directly to the Sat Nav, so you don't need all the electronic gubbins under the tank. I'm not sure if the Starcom offering will fit the Zumo directly as I haven't tried it.
There may be another combination out there that works directly from the Sat Nav.
It is possible to have a hands-free phone conversation from the outside lane of a motorway with my set-up
.(This is on the 1150 GSA - not the Airhead).
Bob.
Paul Rochdale
Registered user
Thanks Bob. I have no need for communications (single seat) nor music or mobile phone (I need to concentrate when riding) just the GPS when I prefer not to take my eyes off the road. It was mostly OK when riding in Belgium/Holland as the roads were so quiet although not so safe when riding in cities.
There was a thread only a week or so ago about being able to listen to GPS messages.
There was a thread only a week or so ago about being able to listen to GPS messages.
The polished rims will be alloy in it's purest form and completely naked to the elements, there'll be no more susceptible material to corrosion. It's entirely possible (and I may be completely off here) that the original rims were bright anodised which has now been polished off.
There are a few solutions-
- Have the rims re-anodised
- Have the rims lacquered
- Use ACF 50 on the rims
- Take a tube of Autosol and a rag with you on every trip
They sure do look lovely though!!
There are a few solutions-
- Have the rims re-anodised
- Have the rims lacquered
- Use ACF 50 on the rims
- Take a tube of Autosol and a rag with you on every trip
They sure do look lovely though!!
Paul Rochdale
Registered user
Chris
You are half right, my friend, but Akront rims are made from an aluminium ALLOY and not at all pure, nor are anodised.
"Akront Rims come from the factory with a standard polish and no anodize coating".
But as you say, they do look nice even if it took a whole hour to restore the bling.
You are half right, my friend, but Akront rims are made from an aluminium ALLOY and not at all pure, nor are anodised.
"Akront Rims come from the factory with a standard polish and no anodize coating".
But as you say, they do look nice even if it took a whole hour to restore the bling.
Chris
You are half right, my friend, but Akront rims are made from an aluminium ALLOY and not at all pure, nor are anodised.
"Akront Rims come from the factory with a standard polish and no anodize coating".
But as you say, they do look nice even if it took a whole hour to restore the bling.
Of course you are right, I was referring to the material being back to naked rather than being pure aluminium.
I would be very surprised if they weren't coated with something from the factory though, maybe a satin lacquer. If they were the bare material they'd corrode within 5 minutes from new.
Paul Rochdale
Registered user
As a point of interest, Bacofoil and those aluminium milk bottle tops we used to have were pure aluminium, and the Supermarine Spitfire was covered with a special aluminium alloy coated to with pure aluminium (called ALCLAD) as the coating resisted corrosion.
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