1992 R80GS Refresh

B Murr said:
Part number for box just in case there are different versions.
Click to expand...

Same part number as mine and confirmed as same dimensions . Only difference is I cut my front rubber bung down to 10mm height and yours is 14mm hence why your tool box is slightly raised at the front whereas mine is now parallel with the rear subframe top member
 
Still waiting on a few parts to finish the bike so decided to fill some time in making a custom rear rack mount so I can attach a 22 litre OEM/BMW top box

I had bought a secondhand rear rack mount off a R100RT and four additional pannier frame clamps , the type used to secure the rear support bar on the pannier frames

After a bit cutting , bending , bashing and drilling I had something knocked together that I was happy with

I think it looks very OEM and not an afterthought

















Last job completed today was to fill the engine oil , gearbox oil and FD oil
 
Brilliant job as ever John. The experience of doing an airhead, vs. G650 series of K Series will have been a lot of fun (and no doubt anguish) but as ever, the result is inspiring for the rest of us mere mortals.
 
Flasher relay arrived today but unfortunately DOA ;-( , waiting to hear back if they can send a replacement

Did manage to fit the missing Headlight Guard







 
Made further progress today but yet again my lack of detailed knowledge on these bikes meant I am waiting on parts

Got the top box plate fitted and also the bash plate







Got all of the PD tank refurbished with new fuel taps . fuel cap , rubber spacers and hinged panel lock & retainer










Came to fit the tank and discovered I needed specific cockpit side panels to suit the PD tank so couldn't fit the tank

I have the standard GS side panels and I need PD ones





I have now managed to get a pair of panels from Germany so will hopefully get them end of next week



Moved on to fitting the single PD seat and additional rack which again as I wanted it to fit alongside the rear top box rack took a bit engineering to sort









Happy with how it came out and the seat lock all works so I can secure it

Also sorted the hazard warning and that is now working once I fitted the correct relay
 
John. On the PD tank, there is a drain hole in the lockable cubby hole/glove compartment in the tank. Check that there is a length of drain hose here, as if it's missing, water pours directly ontop of the starter relay.
My drain pipe was missing and had corroded the relay, so I used a battery vent elbow and some tubing to divert the water.
 
kirby morgan said:
John. On the PD tank, there is a drain hole in the lockable cubby hole/glove compartment in the tank. Check that there is a length of drain hose here, as if it's missing, water pours directly ontop of the starter relay.
My drain pipe was missing and had corroded the relay, so I used a battery vent elbow and some tubing to divert the water.
Click to expand...

Thanks for that , I wondered what the hole was for and whether it should have a drain tube fitted , I’ll see if I can come up with something to sort it

Another question - what is the routing for the fuel cap breather ?


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Usually down the steering columny thing, if there's a hole, mine just flops in the general direction of the forks.

I'm not sure how much is original on mine. My g/s goes down the steering columny thing.

I'm glad to have been really useful. :D
 
tuftywhite said:
Usually down the steering columny thing, if there's a hole, mine just flops in the general direction of the forks.

I'm not sure how much is original on mine. My g/s goes down the steering columny thing.

I'm glad to have been really useful. :D
Click to expand...

The standard GS tank breather goes from under the tank across the top of the engine and down to near the rear brake pivot . I may just leave that in place and put a connector with a piece of breather tube from that up to the PD tank filler cap
 
My 89 non PD has the breather on the fuel cap and the tube goes through the steering stem.
 
ChasF said:
My 89 non PD has the breather on the fuel cap and the tube goes through the steering stem.
Click to expand...

The 90-96 R80GS uses a different fuel cap with no breather , the breather is a steel pipe which passes through the tank from the filler neck to the underside of the tank .
 
Great looking bike and really enjoyed the thread and pictures. Cant help wondering what that white thibg is on your wall though? Is it a heater of some sort?
 
Captain jack said:
Great looking bike and really enjoyed the thread and pictures. Cant help wondering what that white thibg is on your wall though? Is it a heater of some sort?
Click to expand...

Ha Ha it’s an adjustable blackout roller blind covering a frosted window


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Nippy Normans supply Touratech, Wunderlich, Desert Fox and many other makes of accessories.
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