1978 BMW R100S
Purchase Date: April 2018
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Another motorcycle? Yes, another motorcycle.
I've always admired the larger airhead BMW motorcycles. I wanted a black one for a long time but the prices can be just a little out of reach for a motorcycle I can't really justify owning.
A few years back I was the lucky owner of a fun little white R60 and have regretted parting with it. The bike was a great little grocery-getter, unfortunately it didn't make the cut driving on the fast freeways here in the CA bay area. The R60 was also the bike that my girlfriend Hillary learned how to ride on; because of the attachment she still gives me a bit of a hard time for letting it go.
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A few years later, it's 2018 and a black '78 R100S shows up for sale on an email list that I'm part of. The price is good albeit the bike does need some work to make road worthy, this is the ideal scenario for me. I don't necessarily need the motorcycle but how can I pass this up? I think I can justify this one.
The "good deals" get snatched up quickly. We all know this, so I couldn't wait and "think about it", I had to make a move on the listing ASAP. That I did, and the owner promptly replied with photos. I was sold right off the get go.
The motorcycle was located in a small town, northern CA bay area - just under a 2 hour drive for me. Upon arrival I was welcomed with the owner and a few friendly dogs. We walked into the well equipped garage where I was immediately awestruck by the collection of over a dozen motorcycles, a few vintage cars and machining equipment all neatly crammed together in perfect harmony.
The owner and I immediately started to converse about all or the motorcycles and cars surrounding us. So many toys, the owner is a lucky man. It didn't take long before he and I made our way to the R100S resting on a lift waiting for my inspection. I didn't have much to look over, I knew I wanted the bike. The BMW started up with a rough burble and cough, I didn't even expect that much. Without hesitation I let him know I was interested. To make a long story short, we swiftly wrapped up the deal and I was on my way home with a 1978 BMW R100S in the back of the truck.
The 1978 BMW R100S has a 980cc opposed Boxer engine with 2 valves per cylinder. The air cooled engine puts out 56 ft-lb of torque R 6000 rpm. The BMW has a dry, single plate clutch and 5 speed gearbox. Top speed is a modest 118.5 mph. This bike can do the distance with the 6.3 gallon fuel tank. At 484 lbs wet, the motorcycle is equivalent in weight with modern sport touring bikes the same size.
After arriving at home I went to pull the large BMW off the truck finding out the front brakes were practically locked up. I've seen this before on airheads in the same year range, it's typically due to corrosion in the master cylinder clogging the passageways - not letting the fluid circulate. Anyway, I buckled my knee (a minor, painful price to pay for the BMW) while pulling the bike backwards off the truck. A few more struggles later, the motorcycle found itself tucked snugly against the garage wall, in line waiting for a 2nd life. The previous owner didn't drive it, he just bought it to fix up from the owner before that - which never happened; paperwork listed the bike purchased in '98, it's now 2018. That's a few years sitting; I'm surprised the battery held the re-charge just enough to start the bike.
A few weeks later I notice a rather large puddle of oil on the ground underneath the left cylinder head. Looks like a general seal / gasket change is needed, a good start to go over the bike. - Of course this will go along with the front brake master cylinder rebuild. New brake rotors are also in the not-so-distant future for this motorcycle.
The seat is barely hanging on to the frame, the lock and bracket holding the seat are both in poor shape. Something else to give attention to.
I really admire this BMW, I've been hoping to find one of these in the garage for some time now. I'm looking forward to bringing this one back to life.
June 2019
I've had this bike in the garage for over a year now and haven't done a thing with it. I finally have the Beemer on the lift and I'm starting to take a closer look at it.
Final Drive: The fill level screw is gone, just noticed this. And not gone in a good way, the threads are completely stripped - gone. Not to mention the drive has no oil inside. Another item to take care of added to the list.
Braking: The front brake master cylinder was not functioning correctly. I replaced the piston + orings and cleaned up the housing. All in all this was an easy cylinder rebuild. Parts from the Beemershop in Scotts Valley CA. A final flush appeared to do the job and the brakes work well once again.
Valves / Cylinders: I removed the valves and cylinders to "freshen it all up" and found all kinds of fun mistakes done by a previous owner. This includes: stripped threads, cracked - over torqued connections, gaskets where there shouldn't be gaskets, exhaust side adjustments with zero clearance; and I keep finding more errors as I go along. The good news is the cylinders are in good shape , holding to specification. Nothing major wrong surfacing from the tear-down just yet.
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September 2018
Valves / Cylinders continued: Valves have good seating, springs were out of spec - I replaced them with OEM springs from Wunderlich. I also replaced the worn rings with an OEM set from boxer2valve, along with the new gaskets and seals tidying it all up. I personally use blue hylomar gasket sealant, I found that it works best for me.
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Starter: The starter on the BMW was tired. Instead of rebuilding I ordered a new one, an eBay special. The price was right although fitment was sub-par. I found myself making a new grounding bracket along with adding some all-thread for the main mounting hardware. I also discovered a spider nest in the starter handlebar switch along with a faulty wire connection to the relay. I cleaned up the cobwebs and rewired the relay assembly with a new old-stock relay.
Final Drive: The final drive assembly is all cleaned and freshened up, the stripped threads were not as bad as I initially thought.
Wiring: Someone with poor wiring skills had their hands on this BMW at some point. The added / removed / poor wiring that was completed outside the factory harness is poor. Frayed wires, loose connections and un-terminated connections are plentiful and a major headache. I'm correcting and cleaning up everything I come across. At some point, if this motorcycle turns into a long term bike I will replace with a new complete wiring harness.
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After closing up the engine cases, re-installing the carburetors, and wrapping up some of the loose wiring, I attempted to start the bike to find out where I currently stand with the mechanics. It didn't take long for the gas to reach the carb bowls and the vapors found their way into the cylinders when the bike fired right up. It only took a few seconds and the liter bike found itself humming along at a nice steady idle. Ah, what a successful feeling - standing back from the BMW as it sits at a steady idle. The engine is burning off various oils and chemicals on the cases, exhaust odors and the smell of gas, smells good to me!
October 2019
Seat: The seat did not sit correctly on the bike. The seat pan is bent and cracked so bad to the point that the brackets holding the seat to the bike are misaligned. For the mean time, I shimmed the brackets with washers and longer screws for an easy re-alignment, voila - the seat fits again.
Ignition: Currently, the ignition circuit runs well. I am still working out all of the bike's electrical gremlins. I replaced the condenser; the new points are on hand ready to be replaced another day. After everything else checks out.
The BMW has been shuffled around the garage all too long. I'm beginning to get both impatient and excited to get this bike back on the road. I still have to wrap up some wiring on the front end, re-establish mounting for the fairing (original was bent out of place), lube all of the cables, and change the remainder of the fluids. After that, a few test rides - then to clean it all up. I will re-lube the spline, install the new points (+check timing) and re-torque the heads at the same time after some miles have been accumulated.
November 2019
Ignition (continued), Carb Sync: The carburetors were out of synchronization. I re-sync'd them. Installed new points and re-set the timing (using the static, timing light method). Before these updates, the bike had what sounded like a bottom end knock. I initially thought it might be a bad bearing, luckily the sound disappeared after the adjustments.
As usual with these projects, I gave Beemer the a complete service including new plugs, new battery, lubed cables, new fluids, etc...
December 2019
Brakes: Something is going on with the front brakes aside from the master cylinder rebuild; brake fluid is corrosive stuff and it can wreak havoc sitting over the years. I installed new pads and the left side adjusting shaft appears bent, or the lower fork leg is bent, I'm not quite sure at this point what is off. I'll re-assess this problem in the near future.
Test Drives: Upon initial test drives there are some issues. Not surprised on this one, I've been finding one problem after another. The bike runs smoothly, there is a low end knock upon initial acceleration, this may be normal for the year - I'll have to do some research on this before diving into bottom end bearings (no metal filings in the oil filters).
More problems; another electrical short in the wire coming from the starter button housing, not surprised by this being the short is coming from a small bundle of electrical tape that I have yet to inspect.
Update: This short was later corrected, all of the connections in the "bundle" had been re-connected and sorted.
And the wobble! A horrible front end wobble, I believe this is due to dragging left brake. Something is bent or needs a rebuild. The BMW is being pushed aside to work on another day.
More problems; another electrical short in the wire coming from the starter button housing, not surprised by this being the short is coming from a small bundle of electrical tape that I have yet to inspect.
Update: This short was later corrected, all of the connections in the "bundle" had been re-connected and sorted.
And the wobble! A horrible front end wobble, I believe this is due to dragging left brake. Something is bent or needs a rebuild. The BMW is being pushed aside to work on another day.
March 2020
Brake Caliper: After removing the front left brake caliper I confirmed my suspicion, the piston has seized with rust to the caliper. I not-so-gracefully removed the crusty piston and inspected the damage. The caliper piston seating area is slightly pitted, but resurrected after a series of gentle scraping and chemical baths. I purchased and installed a piston rebuild kit from Euro MotoEletrics. Fixed... I have working front brakes with no drag.
Still have the wobble, but it's not so bad. - More to come.
Still have the wobble, but it's not so bad. - More to come.
May 2020
Front End: Tracking down this vicious death wobble, I moved to the next obvious potential solution - the headset bearings, steering bearings. Of course, under my further inspection a previous owner installed an aftermarket top triple tree bracket to replace the weak original setup, this was a good choice although they missed with installing it properly. The main steering assembly nut was not retaining the nut for bearing adjustment, therefore allowing the nut to loosen. And, the main nut was stripped. I went ahead and dis-assembled the headset components; re-greased the bearings, installed a thick washer above the bearing nut and re-assembled with the proper torques and a new OEM main nut.
Testing the bike I was sure to have success in correcting the wobble, unfortunately this was to no avail. It helped a little, but the wobble was still there. Back to the drawing board.
This appears to be in the front end by the feel of the wobble. It only happens when I turn left on an aggressive slow speed turn. It is bad, frightening even therefore not safe, not drive-able.
After reading through blogs on the internet I keep reading about a bracket behind the tool box being broken or loose and/or potentially the swingarm bearings being loose. Both of these are easy to inspect so I went to it, the bracket is intact, no problems there; next.. The rear swingarm... wait. A previous owner that messed all the other stuff up also had the rear off. I felt the rear for play and sure enough that's it! The rear swingarm bearings were very loose!
Testing the bike I was sure to have success in correcting the wobble, unfortunately this was to no avail. It helped a little, but the wobble was still there. Back to the drawing board.
This appears to be in the front end by the feel of the wobble. It only happens when I turn left on an aggressive slow speed turn. It is bad, frightening even therefore not safe, not drive-able.
After reading through blogs on the internet I keep reading about a bracket behind the tool box being broken or loose and/or potentially the swingarm bearings being loose. Both of these are easy to inspect so I went to it, the bracket is intact, no problems there; next.. The rear swingarm... wait. A previous owner that messed all the other stuff up also had the rear off. I felt the rear for play and sure enough that's it! The rear swingarm bearings were very loose!
Rear-Swingarm bearings: Luckily I had the milled down socket tool from another project to access the large lock nut for the swingarm. I found the spec for tightening the nut and lock nut and went at it, centered everything up and then tightened and re-torqued everything.
I couldn't wait to take the BMW out for a ride to test for the wobble. Sure enough it was gone! Pfew. Another problem chased down.
A week later I scheduled myself for a safety check ride with the R100S to see if there was anything else I needed to immediately address. The bike ran great as expected. Next I am going to go back through the bike and fix/replace all the odds and ends to bring the bike truly back up to speed.
I couldn't wait to take the BMW out for a ride to test for the wobble. Sure enough it was gone! Pfew. Another problem chased down.
A week later I scheduled myself for a safety check ride with the R100S to see if there was anything else I needed to immediately address. The bike ran great as expected. Next I am going to go back through the bike and fix/replace all the odds and ends to bring the bike truly back up to speed.
July 2020
Sticky Clutch: The clutch would get erratic and "sticky" after the engine gets hot. I installed a new clutch cable, the original was well worn. At the time of the clutch cable installation, I also dis-assembled and inspected all of the clutch assembly components up to the throw-out bearing; cleaned and lubed everything during re-assembly. It is critical on these to set the length of the cable at the bars, then make final adjustment at the clutch side. This cleared up the sticky situation.
Gas Cap: This bike, being a '78 is one of the few years there were gas cap venting issues. I followed the BMW service recommendations and drilled a 1.0mm hole on the underside of the cap, center 22.0mm deep. I can hear the gas gurgle now when I twist the petcock 1st thing in the morning.
January 2021
Brackets: I removed all of the brackets for the bags, including rear luggage rack. Gives a cleaner profile, don't need the carry space anyway.
Seat: The seat still had the original cover, torn and stiff (uncomfortable). I installed some new vinyl skin, Saddleman brand for motorcycle seats was used. I also fixed the broken seat latch, key still doesn't work - at at least it latches correctly.
February 2021
Clutch: The loud knocking noise wasn't going away, that plus the small drip of oil under the bike every now were both enough reasons to inspect the clutch area. Findings, a bad - leaking seal and a bone dry spline. The friction plate had some odd wear as well. I replaced the clutch, friction plate, spring plate and the entire thrust bearing assembly. I got most, if not all of the parts from Euro Motoeletrics.
After wrapping this up, the airhead now runs like it should. No more loud rapping noise after getting hot. Shifts much smoother as well. My best guess on both of these was the dry as a bone spline gear, makes sense that after it got hot it got sticky.
After wrapping this up, the airhead now runs like it should. No more loud rapping noise after getting hot. Shifts much smoother as well. My best guess on both of these was the dry as a bone spline gear, makes sense that after it got hot it got sticky.
April 2021
Mufflers / Header: While putting back together the bike after being inside the clutch, I discovered some bad degradation within the exhaust cans. Plus, they were rust welded to the headers for who knows how long. For the life of me I could not remove them. I sourced and purchased a set of chrome Hoske Sport mufflers from Boxer Metal. For the headers, I found a set of Mac, black ones severely discounted to the cost I couldn't turn down - not mentioning that source.
After some minor fitment issues and carb tuning / balancing, the new cans sound great. Much better than stock. They are louder than stock, with the baffle still in. Significantly louder, but not too loud - just right. As far as performance, I can not tell if there are any power gains or losses.
After some minor fitment issues and carb tuning / balancing, the new cans sound great. Much better than stock. They are louder than stock, with the baffle still in. Significantly louder, but not too loud - just right. As far as performance, I can not tell if there are any power gains or losses.
December 2021
Steering Damper: I sourced and installed a general 330mm steering damper and fork mount. It works great, is adjustable for 7 clicks (if I remember correctly) and completely takes the unwanted mild shimmies out of the front end.
Leaky Bowl: The right side carb has been leaking fuel after the bike sits for a week or so. The leak is oddly coming out of the right side exhaust. I had problems with this carb in the past, it was cleared up for a while - the leak seems to have since resurrected itself. I installed a new float needle which stopped the leak.
January 2022
More Brakes: The rear brake master cylinder has been leaking brake fluid onto the exhaust. I initially thought the splatter was from road grime although it kept coming back. This is when I found the leaky master cylinder. I purchased a rebuild kit from EME and a new Brembo hose fitting w/ rubber seal from OPP racing. The rebuild was a bit tricky at one moment as to the washer and gasket orientation, once I figured it out the kit worked like a charm. I also installed a new Tygon brake hose. The pics do not do it justice.
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February 2022
Shocks and springs: Actually just springs. The bike came to me with Progressive Suspension shocks, decent shocks for the bike although they were a bit under-sprung for my weight. I purchased and installed a set of "HD" heavy duty springs. They do the trick and no more tail end bobbing going around corners.
Carburetors: The right side carb was leaking again, - after cold starts. Something strange is going on here... So I did a rebuild. During the rebuild I installed new white style floats and removed the 4x single pods with brass guide rails (rotary tool). While inside the carbs, on the problem one I found a hairline crack on one of the jet ports. I was able to seal it during the re-assembly process. So far the leak appears to have stopped, no more gas odors in the garage. I also installed some small in-line fuel filters just in case any small unwanted particles might have been getting into the bowl.
October 2022
Carburetors - more: Enough with the carburetors already! The right carb will not stop giving me problems and I'm tired of the gas leaks in the garage. Time to upgrade. I've always wanted a reason to install flatslides on one of my bikes, here's my opportunity. I purchased, installed + tuned a set of Mikuni TM34 flatslides. I got them for a great price with adapters included from Mikunioz out of Austrailia. Install was simple and final tuning was fairly close straight from Mikunioz with thier "American gas" pre-sets. Thank you Mikunioz!
Leaks no more. Carbs are excellent! Linear acceleration, great pull. I'm a happy customer. Plus I think they look great.
Cables: Because of the new carbs, the original throttle cables do not work. I made my own cables from one of the DYI kits from Venhill, got the lengths just right and soldered them up. It was a bit frustrating because I had to grind the brass barrels pre-soldering to fit the BMW throttle housing, but I got them to work and I had enough cable left over to make a spare line to keep under the seat.
Leaks no more. Carbs are excellent! Linear acceleration, great pull. I'm a happy customer. Plus I think they look great.
Cables: Because of the new carbs, the original throttle cables do not work. I made my own cables from one of the DYI kits from Venhill, got the lengths just right and soldered them up. It was a bit frustrating because I had to grind the brass barrels pre-soldering to fit the BMW throttle housing, but I got them to work and I had enough cable left over to make a spare line to keep under the seat.
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Petcocks: To ensure I do not have any (more) gas puddles in the garage, just in case the carb float needle gives up, I rebuilt the Germa style fuel petcocks. It's often recommended changing the petcocks entirely to the Karcoma style, which I may do in the future if these rebuilds don't hold up, but I don't see why they won't. Very simple concept and easy to rebuild the sealing surfaces. So far so good.
January 2023
Tires: I recently removed the ageing Continentals and replaced then with a set of cost efficient Dunlop D404's, 100/90-19 and 110/90-18 to be exact. I am happy with the new wheels especially since I found out that the Conti's were way out of balance from the previous owner. Now, with my balancing and install the new set is rolling nice and smooth.
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February 2023
Saddlebags: I wanted something simple to carry a few tools, sweatshirt, some groceries and I don't want to install the Krauser bags. I had a set of old Willie and Maxx saddlebags laying around the garage. I decided to install those for the time being. I'm happy with the way they look, I'll leave these on for a bit and see if I get attached.
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August 2023
Brake lines: The front brakes work good but the disks are bad and the brake lines are ageing. I have a new set of used disks off a R90 that I got for a good deal, I'll install those one of these days. But for now I sourced and installed a new set of "blue" stainless steel braided lines from Galfer.
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Grips and Mirrors: Out with the old sticky worn out handgrips in with the new Ourys. Also, swapped out the bar end mirrors for a single small mirror on the left side. The small mirror may not function as well as the large bar end ones but in my opinion the bike looks better with it. The beemer is coming along little by little.
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Photos and details of the R100S will be added as the project matures.