Airhead 80-100 G/S Adventure Build

Nin · Jun 29, 2021

A quick out of hours PM to Mikeyboy …. Special service tool no 1 and no 2

Tap tap and out they all pop

Then assemble and bag up the new ones, ready to fit.

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Nin · Jul 10, 2021

A few steps forward and a few back in the last few days.

In an idle hour I got all the new hoses into the airbox

Nin · Jul 10, 2021

Then started to get the upgrade (post ‘85) rockers fitted to replace the originals.

Got all the parts laid out

Who can spot the conundrum?

Nin · Jul 10, 2021

Bollox- on the blower to Motorworks immediately, who couldn’t have been more helpful (thanks Stuart).

Apparently this is the second time a part has been incorrectly bagged at BMW, so now they have to check every part they get in fromBMW before it goes out.

Today’s post delivers the right one .

Nin · Jul 10, 2021

So on they go - head gaskets first

Nin · Jul 10, 2021

(I just put that in to wind up Mikeyboy)

Push rods in after goosing up with oil

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Nin · Jul 10, 2021

Nice new nuts and washers, a bit of anti seize

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Nin · Jul 10, 2021

Tighten up and measure clearance - looking for 0.03-.0.07 mm between the nylon bush and post.

Nin · Jul 10, 2021

Tight sliding gap was 0.6 mm so in go 0.55 mm shims

Button it all up again to torque - remembering to mark off each one as its torqued cos I can’t remember anything these days.

Nin · Jul 10, 2021

Adjust tappets and we’re done. Front of engine next …

Nin · Jul 10, 2021

Ah but just realised I’m waiting for the camshaft carrier bearing to arrive, so let’s go to the back instead.

Don’t forget to fit this little fecker before the gearbox goes on or you’ll have to take it off and do it again…

Well that was easy.

Nin · Jul 10, 2021

Next it time to fit the block vents

FFS don’t drop this

In here

Phew. Probably should have done that much earlier in the process to avoid the stress.

Nin · Jul 10, 2021

Next it’s time to fit the most expensive starter motor in Christendom.

Nin · Jul 10, 2021

The dog has reminded me it’s walk time.

mikeyboy · Jul 10, 2021

Don’t want to be the bearer of bad news,
But,
The neutral switch should have a 2mm thick alloy washer on it :comfort

Nin · Jul 10, 2021

Cheers Mike - yes I found that in the bag taped to the box. That’s an old photo of the switch. Good spot though! Did you like the head gasket …

charlie batty · Jul 10, 2021

...in my ignorance i didn't know a neutral switch went there...until I found an extra hole with no nice S/S plug in it

Managed to get it in by supporting the engine/box with a jack and sliding the rear engine bolt and central fat spacer out ... was a ball-ache though but worked :aidan