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Old 02-01-2010, 08:36 PM   #1
One Less Harley OP
OH.THAT'S GONNA HURT
 
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Joined: Nov 2006
Location: Bowling Green, Ky
Oddometer: 4,655
Wrenching on my R80 G/S, an ongoing therapy

1984 R80 G/S WB1034803E6362926

1) 05/6/86 Purchased New from Psycle Therapy, Columbus Ohio by B Grimes (Urbana Ohio).
2) 4/16/98 Purchase from Competition Accessories (Springfield Ohio) with 57,4557 miles, C. Roelling (Miamsburd, OH), for $1,500
3) Gunner65 purchased and only had it for 3hours
4) Lexington owner purchased it from inmate Gunner65
5) 09/11/2008 One Less Harley (KY) with 95,000 miles from a guy from Lexington KY, who didn't own it very long.

According to Gunner65 the bike has been to Alaska at least twice. Cosmetically challenged when I purchased it, mechanically very good and well maintained. Very clean oil oil pan w/ no sludge. Nice original example. Bike now has a R100GS front end, 4 pot Brembo, Taller 5th gear, top end rebuilt, Enduralast, repainted blue.

Links to miscellaneous post-

1) Death Wobble

2) Connecting Volt guage to G/S

3) Bosch Starter Repair, Bendix Replacement


4) Motor won't turn over, this is unusual-Starter related

5) Clutch Balance marks

6) Head job, rings, rod bearings-good post

7) Painting HPN tank (polyethlene)??, why not?

8) 320mm brake upgrade

9) Tanks to fit an R80 G/S

10) R80 G/S upside down brake arm conversion

11)
Fix for Acerbis (OMG) petcock, left and right ones now point the right way

12) Transmission rebuild mislabeled 17.5 degree primary gear


13)
BMW Performance School

14)
Trail Tech MR16 HID lights are crap, 2 lights 2 failures!!!

15) 4 Pot Brembo Caliper conversion for GS

16) Damned neutral switch again!!!

17) Airbox Engine Breather Modification

18) Happy Trails Top Mounting Bracket Fix

19) Page 3, Post #45 ring gear bearing replacement

20) Page 5, post #65 R100GS front end

21) Page 1, post #10 Flywheel Issues, no rivets

22) Float bowl leashed Sololobo's article

23) HH Race Tech R100GS fork inserts.

24) Final Drive Breather Hose

26) Carb jetting Changes and notes

27) Hanging Idle discussion

28)
Larger Foot Pegs from KTM

29) R80G/S to 2012 MOA Rally via the TAT

30) Float Bowl Leashes

So here's the old gal as purchased, notice the big honking headlights and angle irons for brackets.



...and here it is now.



One of this first things I did was drop the oil pan to check for gunk in the engine and check the oil pickup. I've heard these can loosen up. All was well inside along with changing all the fluids, that included the brake fluid.



Next on the project was to pull the tranny and lube the splines, plus since the rear frame was off why not powder coat it???



Then a custom muffler guard for the Sito Muffler out of plain metal rods.
Look here for link

http://www.advrider.com/forums/showthread.php?t=387232






Then some eyebrows for the large PIIA's as I was getting a glare from the top edge.




Then reinforcing stock racks for the Happy trails panniers. Gussets added.





And a rear bar, stood up to a good crash, but probably should be bigger.



Happy Trails bags mounted plus new paint on tank and side covers. I had the original blue tank scaned for a color match. This tank is from a R100GS with the seat tab cut off.



Cut down side cover for muffler and accessory plug added.




1st installment hope I haven't bored anyone w/ the repost!!
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2004 BMW R1150RS
1984 BMW R80G/S
(wrenching index)
2003 Suzuki DRZ 400S (TAT Prep)
One More DRZ does the TAT (Ride Report)


One Less Harley screwed with this post 02-26-2014 at 02:00 PM
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Old 02-01-2010, 09:14 PM   #2
Infracaninophile
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In.

I wonder if there's any way for the Mod to "Join" your old posts to your new thread. I know Mods can do it. Perhaps if you get the info, Putts could do the heavy lifting. Just a thought.

T.
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Old 02-02-2010, 02:53 PM   #3
R12Battletub
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I noticed you have the larger brake rotor in the later pictures. How do you like it? Did it make much of a difference?

Cheers, Gunther
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Old 02-02-2010, 04:19 PM   #4
Rucksta
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Quote:
Originally Posted by R12Battletub
I noticed you have the larger brake rotor in the later pictures. How do you like it? Did it make much of a difference?

Cheers, Gunther
One Less

I went back to have a look and the "original" rotor on the standard looking carrier. It is quite interesting. It seems to be a floater or semi floater judging by the big buttons. Any idea what is was and where its from? Is it still around? Can I have it please?
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Old 02-03-2010, 05:36 PM   #5
One Less Harley OP
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Quote:
Originally Posted by Rucksta
One Less

I went back to have a look and the "original" rotor on the standard looking carrier. It is quite interesting. It seems to be a floater or semi floater judging by the big buttons. Any idea what is was and where its from? Is it still around? Can I have it please?
What is it that your are asking??? The original rotor is a "floater" the 320 has some laser cuts to allow for heat expansion. I'm keeping my original rotor.

Personally I like the 320mm conversion, I can now lock up the front wheel, does anyony really need a 48 piston front brake, just kidding about a 48 piston brake, but six piston seems a little overkill, maybe I'm not ridding hard enough or carrying that much weight.

Sololobo wasn't that impressed with the 320mm and stock caliper I think he has higher expectations.
__________________
2004 BMW R1150RS
1984 BMW R80G/S
(wrenching index)
2003 Suzuki DRZ 400S (TAT Prep)
One More DRZ does the TAT (Ride Report)

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Old 05-02-2010, 02:15 PM   #6
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Silly me forgot I was trying to post my wrenching in one place, so to move this topic to where it needs to be----

R80 G/S, loose change sound


I've noticed an unusual noise from my R80G/S. It is noticed when shutting off the engine and at idle. Noise does not go away when pulling in clutch at idle.

Sounds like a metallic rattle, briefly when shut down, basically like loose change, clanging together. Not overly noisy and most people probably wouldn't notice.

I'm thinking it may be the starter, which had new bendix installed last year.

I've put a screwdriver up to the heads and the front cover and listened, no unusually noises there.

Recent work done, tranny installed, valve and ring job.

Any thoughts???
__________________
2004 BMW R1150RS
1984 BMW R80G/S
(wrenching index)
2003 Suzuki DRZ 400S (TAT Prep)
One More DRZ does the TAT (Ride Report)


One Less Harley screwed with this post 07-29-2010 at 08:04 PM
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Old 02-02-2010, 04:22 PM   #7
One Less Harley OP
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Joined: Nov 2006
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320 MM brake upgrade

Instead of reposting what has already been discussed I will supply one picture from the post and a link to the discussion. I think this will work out best, not to mention easier!

For my post and pictures on the 320 mm brake upgrade look here...

http://www.advrider.com/forums/showthread.php?t=431606




or thoughts of adding a second disc brake to the G/S, check out link below-

http://www.advrider.com/forums/showthread.php?t=429709
__________________
2004 BMW R1150RS
1984 BMW R80G/S
(wrenching index)
2003 Suzuki DRZ 400S (TAT Prep)
One More DRZ does the TAT (Ride Report)


One Less Harley screwed with this post 02-02-2010 at 05:35 PM
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Old 02-03-2010, 02:22 PM   #8
Beater
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Nice. Keep it coming ...
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'85 R80RT G/Sified <|> '91 R100GS Bumblebee (103K miles and climbing) <|> '73 R75/5 LWB
Airhead Zen: Ride - Repair - Ride - Maintain - Ride - Repeat
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Old 02-03-2010, 05:35 PM   #9
One Less Harley OP
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If I get off my but and don't feel to guilty about not working, I'll post on the upside down brake lever and some post on replacing the drive and driven bearing on the final drive.
__________________
2004 BMW R1150RS
1984 BMW R80G/S
(wrenching index)
2003 Suzuki DRZ 400S (TAT Prep)
One More DRZ does the TAT (Ride Report)

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Old 05-10-2010, 08:21 PM   #10
One Less Harley OP
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Larger KTM footpegs made to fit.

A while back I was out ridding w/ the stock foot pegs and rubber inserts which become slippery when wet. So I removed the rubber and at least the pegs were grippy. The stock ones are quite narrow so I wanted to see what larger ones would be like, plus not wanting to spend a lot of money on pricey aftermarket ones. So to the garage w/ a cutoff tool, welder and some scrap metal.........



The top foot peg is the stock one, the lower is from a 1996 KTM 300MXC (aka POS) I once had. The swivel mount was too wide so it was cut off.

A new mount was made out of scrap flat stock



The metal was relieved to make 90 degree bends then welded up.



Holes were drilled into the new mount, sorry no pictures, then the KTM platform was situated to be close to the original footpeg location. Then tack welded in place, adjusted then welded completely.






__________________
2004 BMW R1150RS
1984 BMW R80G/S
(wrenching index)
2003 Suzuki DRZ 400S (TAT Prep)
One More DRZ does the TAT (Ride Report)


One Less Harley screwed with this post 05-10-2010 at 08:30 PM
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Old 05-10-2010, 09:31 PM   #11
hardwaregrrl
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Nice....

I got me some moose racing open package pegs at cycle gear for 40 bucks!!! Welded new stops on and good to go!!!
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Old 05-12-2010, 08:23 PM   #12
One Less Harley OP
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OEM Sump Gaurd, and Twin Headlight Earnie's Center Stand Guard

Newest addition to the G/S- Sump and center stand guards. I tried to get the OEM BMW center stand guard, but they were NLA, so The other option was the Twin Headlight Earnie one, which looks better and mounts better than the OEM, but the Earnies' sump guard was not a design I liked, the rigid attachment to the sump was unacceptable. I decided against it after seeing Hardware Girl's on the ST.

I purchased the sump guard, bolts, rubber spacers and washers from Chicago BMW and as luck would have it there were none in the USA, but there was ONE left in Germany. YEAH THAT'S RIGHT ONE.....ONE ...ONE, WHICH MEANS THAT THERE WILL BE NO MORE OEM ONES EVER!!!! I don't think they will be making any more ever again.



A shot of the 22mm headed bolts (note the shank on the bolt), rubber spacers, and flat washers which mount between the rubber and sump.



Another shot of how the mounts are assembled.



Another view of the guard.



A comparison shot between the little bitty stock guard, note the cooling vents, sure wish the big on had these!!



and it mounted, yes the guard is really close to the exhaust pipe, so close I had to loosen the exhaust clamp and fined nut and move the pipe a little to clear the guard.



A nice neat fit to the Twin headlight Earnie center stand guard.

__________________
2004 BMW R1150RS
1984 BMW R80G/S
(wrenching index)
2003 Suzuki DRZ 400S (TAT Prep)
One More DRZ does the TAT (Ride Report)


One Less Harley screwed with this post 05-12-2010 at 08:48 PM
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Old 05-12-2010, 08:52 PM   #13
hardwaregrrl
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Hey Richard...

looks really nice. and sharp!
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Old 05-12-2010, 09:06 PM   #14
One Less Harley OP
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BTW, no pictures here as I was in a hurry, but my front brake was a little soft so, since I had the caliper and master cylinder kits on hand, I rebuilt them a cople of days ago. Lots better pressure at the lever.

Pretty easy to do, just needed snap ring pliers to get the piston out of the MC, then for the calipers, compressed air to push out the pistons, (keep your fingers clear), a small pick to snag the piston seals. then just clean the parts well. The mastercylinde and calipers bores were in good shape so the master cylinder bore was lightly sanded and cleaned again, then seals and bores lubed with brake fluid upon assembly.
__________________
2004 BMW R1150RS
1984 BMW R80G/S
(wrenching index)
2003 Suzuki DRZ 400S (TAT Prep)
One More DRZ does the TAT (Ride Report)


One Less Harley screwed with this post 05-12-2010 at 09:20 PM
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Old 05-13-2010, 04:57 AM   #15
AntonLargiader
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Location: Charlottesville, VA
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Quote:
Originally Posted by One Less Harley
... yes the guard is really close to the exhaust pipe
It's the wrong sump. That skid plate matches the smooth-bottom sump, not the early GS and /5 sump.

The smooth sump is slightly deeper: http://www.largiader.com/tech/oilpan/
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