Corona Virus Side Effect

byron · May 11, 2020

Well folks I thought it was time to talk about the way the lock down has affected me.About 3 weeks ago I pulled my r90s out of the garage for the first time in 4 years after a restoration and I also pulled the 80 g/s out along side to take a few pics for a friend of mine. The g/s had a little trickle of oil on the bottom of the sump and closer inspection revealed that the oil was coming from a pushrod seal on both sides and either the neutral switch or the back of the engine. In a mad "Covid moment" I pushed it up on the ramp to have a look.

byron · May 11, 2020

Here are a few photos

byron · May 11, 2020

Anyway the first thing to do was to look at the front brake and fork area. Polish the front rim , rebuild the front caliper, reroute the front brake pipe and add a new new brake hose.. I also decided to replace all the nuts and bolts with stainless. A few days later I was quite pleased with the result but I still had not sorted the oil leak . However the bike look quite nice from the front and still no prospect I'm going out on it. The prospect of this virus to a 65 year old can do funny things.

byron · May 11, 2020

Anyway my next thought was to sort out the push rod tubes so of course the exhaust had to come off. When I bought the bike I hadn't realised that the Collector box had been tack welded to the exhaust pipes. B***** and s*** it and I need to get my hacksaw out and check with Motobins £350 agh!!
So I remove the barrels and head on both sides and at the same time I ordered a 800 CC gasket kit. When the kit came back I found to my surprise the head gasket wouldn't fit and through a thread on the forum I was told the bike had been upgraded to 1000cc. Ordered two new gaskets ( does anyone want a pair of 800cc head gaskets for £10
posted ). I don't know if I am pleased or not to have this upgrade to a larger bike , but I did think it was a bit more lively compared to my 1989 80 GS when I got it last April. So decoke and valves lapped and re assembled.

byron · May 11, 2020

If only I could put pictures in the right way round !

byron · May 11, 2020

A few more pics of the pushrod work.

byron · May 11, 2020

So with one oil leak sorted out it was time to look at the difficult one. Was it the the Neutral switch or was it it behind the flywheel . So I made the rather rash decision to look at the main crank seal and oil pump seal. The bike had been almost un - used for almost 10 years and my 2500 miles on her last summer had probably upset all sorts of bits of rubber etc . So I pulled it apart last week . So off with the swinging arm , output seal leaking. Removed the gearbox and all 5 seals need replacing!!!! So at the weekend I removed the clutch and found it needed a new friction plate and then went on to look at both seals at the back of the engine and they were just about dry ,but a slight mist near each of them. However the Neutral switch on the gearbox was leaking like a colander. So back to motor bins for another £100 worth and clearly this coronavirus is taking its toll on me

barny · May 11, 2020

It's amazing how much entertainment you can get from 1 oil leak. Good luck with the partial rebuild. Just think you've still got the 90 to look at.

byron · May 11, 2020

On Sunday I decided to take the plunge and remove the clutch and and a flywheel. After a quick check on YouTube I released the clutch only to find and the original plate was almost down to the rivets.With the motor at tdc I remove the flywheel finding the area slightly damp with oil mist.The main crankshaft seal proved very problematic and braking my seal puller . So it had to be carefully crushed inward to release it. The oil pump bolts also proved difficult to remove. I am wondering if this bike has been immersed in water sometime and some of the fittings seem corroded in place . All were removed and replaced with new. I have a powder coated steel tee piece to fit in the end of the crankshaft to stop movement and I used a wooden disc to pull the seal home.So a new clutch and gearbox 6 gearbox/ final drive seals ordered from Moto bins last night.

byron · May 11, 2020

Yesterday's photos

A few more photos

byron · May 11, 2020

I'm now completely up to date with the work and this morning I decided to take the front cover off and change the timing chain together with gaskets and oil seals as I am going to have to wait a few days for the new clutch plate to arrive and I already had a timing chain set here from a previous project. The timing chain cover looked a little tired so I thought I might repaint that as well. It was actually quite easy to remove the beancan ,alternator and diode board together with the associated wiring. Lots of photos were ta6to help me remember, I am 65 after allThe timing cover came off really easily and didn't require the use of a puller or any heat fortunately . I also noticed that the starter cover needed painting ,but unfortunately it has some damage around one of the the screw holes. If anyone has a spare cover they would like to sell me please get in touch as I must replace it in the near future. So this morning I sanded and painted the timing cover ready to sand the ribs tomorrow. After lunch I remove the chain together with the tensioner and guide and replaced them with the new items. All went really well except the fitting of of the Loose link was a bit tricky and needed the use of forceps. Anyway all done now I'm ready for assembly tomorrow. This lockdown has certainly made me do a lot to this Paris Dakar bike.

byron · May 11, 2020

Some more photos

gog · May 12, 2020

nice work byron. i probably have a starter cover kicking about that you can have.

barny · May 12, 2020

If its any help to you or others the guy who does the Phoenix Video's on Utube uses a cable tie to pull the chain together to fit the split link. You seem to be doing a lot of good future proofing so at least you will have confident in the long term good luck. I may start looking at my GS soon with the same view.

byron · May 12, 2020

Thanks chaps , the 2 800cc gaskets are now sold.

michaelmy · May 12, 2020

Hi Byron

Nice bike, and great work!

You seem to have R100 GS forks, with a brake conversion on it?

Any ideas where that conversion came from - the adaptor, disc & calliper?

Thanks!

mikeyboy · May 12, 2020

I will almost certainly have a starter cover if gog hasn’t

byron · May 12, 2020

That is very kind of you both

byron · May 12, 2020

michaelmy said:
Hi Byron

Nice bike, and great work!

You seem to have R100 GS forks, with a brake conversion on it?

Any ideas where that conversion came from - the adaptor, disc & calliper?

Thanks!

You are right, when I bought the bike in March 2019the 100gs forks were already fitted as was the Brembo p4 caliper. However the bike was still using the 80 g/s mangled brake pipe. So I have made a new pipe to fit snugly and fitted a new brake hose. This system gives brilliant 1 finger braking. The bike also came with the correct forks,brake and wheel ,but I doubt I will change it any time soon. I am wondering if the rather neat adapter bracket was a one off. The guy I bought the bike from imported it from Austria in 2010 and I think only used it in the first year. Here is a picture I have found of the bikes Austrian owner in 2010. He is a hotel owner and I have subsequently found pictures of the bike on the hotel web site.

byron · May 12, 2020

Spent another few hours working in the garage today. Having painted the timing chain cover yesterday, then I spent a few hours sanding the fins to reveal the aluminium. This is quite a tricky and time consuming and for me a great deal of care is needed. Finally I gave the front cover a clean and polish. All now should be ready to be added to the bike tomorrow. I had a surprise in the post today when I received the output seal nut extractor. This tool came from the bmriders club which is a great club .

Corona Virus Side Effect

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