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Old 06-07-2013, 10:09 PM   #466
TINK OP
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Joined: Nov 2007
Location: So Cal
Oddometer: 668
Parts List

Just for the record, here are the parts I bought for the job. Total cost $560 at Irv Seaver's


1979 (0978) BMW R100RT


21 21 1 234 035 DIAPHRAGM SPRING (to 09/80) x1

21 21 1 251 801 PRESSURE PLATE (to 09/80), x1

21 21 1 236 332 CLUTCH PLATE - VERSTAERKT (to 09/80) x1

21 21 1 231 666 COMPRESSION RING (to 09/80), x1

***

11 11 1 338 342 SHAFT SEAL - 100X80X10, engine rear main x1

Rear main seal. You have to pre-form the seal to flywheel (1970-1980) or to flywheel

guide ring (1981-1995) airheads.

11 41 1 335 895 O-RING, oil pump x1

Fits all Airheads, 1970-1995.

11 22 1 337 099 GASKET RING (from 09/78), flywheel inner o-ring x1


***

21 21 1 231 463 FILLISTER-HEAD SCREW (to 09/80), clutch plate bolts x6

11 22 1 262 060 HEX BOLT - M11X1,5, flywheel bolts x5

07 11 9 913 464 HEX BOLT - M6X16 (to 09/80), oil pump cover bolts x4

***

07 11 9 963 130 GASKET RING - A12X15,5 AL, drive shaft oil drain/fill x2

26 11 1 242 297 SCREW - M8X1, drive shaft bolts x4

These short bolts 26111242297 fit 1981-1995 Airheads; do not use washers.

TINK
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Old 06-08-2013, 11:19 AM   #467
TINK OP
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Clutch by SACHS

Some pics of the SACHS clutch disk markings.



New style rear main seal soaked in oil over night and then fitted to flywheel


TINK
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Old 06-08-2013, 11:34 AM   #468
Big Bamboo
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Helping a friend put together a 1978 R100/7

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Old 06-12-2013, 11:10 PM   #469
TINK OP
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Flywheel Install

Nice build Big Bamboo.

Put the rear main seal and oil pump o-ring in and installed the flywheel tonight...

New rear main seal installed


Ready for flywheel



Ready, set, go...


Torque those bolts to 75 ft lbs


New clutch diaphram spring


New clutch inner plate, note the three installation alignment studs


$560 bucks sitting there...


Let my crankshaft FREE!


TINK
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Old 06-13-2013, 07:37 AM   #470
TINK OP
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Question 7.3 footpound

Did I screw up?

After I finished putting the flywheel on I cleaned up my tools for the night and went to check off the items on the instruction sheet I've been following.
That's when I read this...

"careful to tighten the 4 bolts evenly, in a cross-pattern, a bit at a time, until tight....88 INCH-pounds (that is only 7.3 footpounds)."
http://www.bmwmotorcycletech.info/fl...valwarning.htm

I was very careful about lapping the oil cover face, greasing the o-ring, aligning the cover. used a drop of blue lock, tightening the bolt in a cross-pattern... But I have no idea really what I torqued the nuts to... I tightened them with my nut-driver handle (see "Ready, set, go..." picture above) then hit each one with 1/2 a grunt with my 3" ratchet.

1) Is the fear hear to not strip out the threads in the engine case? If so, then I'm fine.

2) Is there any chance the o-ring can be over compressed? I can't imagine, but I'm no BMW expert.

3) Have I become the typical curmudgeon BMW owner who frets about ever .001 ft lb of torque and .001 cc of oil?

I believe the answer is #3 (and #1).

OMG will I start loosing sleep at night every time I touch a bolt on my BMW!?

It's not too late to take the flywheel back off and replacing the o-ring, again.

What does the audience say...

TINK

TINK screwed with this post 06-13-2013 at 07:45 AM
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Old 06-13-2013, 09:34 AM   #471
kaput13
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Nice pictures! Its been fun following your progress. I'm sure you know that your work is a little messy though and you will want to clean up your garage.

Tink says: "I tightened them with my nut-driver handle (see "Ready, set, go..." picture above) then hit each one with 1/2 a grunt with my 3" ratchet."

Yes to #3. I happen to know that this equals 7.3 foot pounds exactly. You can go to sleep.
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Old 06-13-2013, 08:14 PM   #472
Kai Ju
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Quote:
Originally Posted by kaput13 View Post
Nice pictures! Its been fun following your progress. I'm sure you know that your work is a little messy though and you will want to clean up your garage.

Tink says: "I tightened them with my nut-driver handle (see "Ready, set, go..." picture above) then hit each one with 1/2 a grunt with my 3" ratchet."

Yes to #3. I happen to know that this equals 7.3 foot pounds exactly. You can go to sleep.
+1 on every point.

But if it makes you feel any better, the o-ring cannot be over compressed since the cover "bottoms out" on the back of the block. If you didn't strip the screws you're good to go...to sleep.
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Old 06-14-2013, 07:56 PM   #473
TINK OP
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Turn Signal Screws

So, you've lost a turn signal lens screw and you local BMW dealer tells you they are no longer available...

You start with the local hardware store, move up to the specialty hardware suppliers (Hillco for example), but no joy on a M3.5 "fine thread" x 25mm machine screw.

Next you turn to the web, and you find several sources but they want $3 / screw + shipping, Sheesh Boo Boo.

Put on your thinking caps... who might have a M3.5 fine x 25 machine screw!?

Dubro to the rescue! Yes, Dubro part #2274 is what the Dr. ordered.

Sure, purists won't like the fact that the Dubro screw is an Alan head and black oxide, too bad, go ahead and spend your money on those $3 + shipping screws and have a nice day.





Oh, ya, and if you're looking for a substitute for the BMW washer for the turn signal lens screw, this Honda part fit's perfectly.


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Old 06-14-2013, 08:00 PM   #474
TINK OP
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Clutch almost done


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Old 06-14-2013, 08:43 PM   #475
TINK OP
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Got to fix that some day... "today" was some day

The neutral switch connectors are a real PITA to plug in once the transmission is in place. I managed to get the connectors back onto the neutral switch the first time I had the trans out during restoration...

but no such luck today. I had the trans in and struggled to get the connectors onto the neutral switch...

wouldn't ya know it, S N A P the connector breaks off from the switch.

Pull the trans back out, install new $35 neutral switch, build sub-harness so I can plug the wires onto the switch while it's still on the bench, modify the BMW harness to fit the new sub-harness, re-install trans.

Bummer!


New sub-harness


Modified BMW harness


Trans install, NO PROBLEM now with neutral switch sub-harness


Done!


TINK
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Old 06-15-2013, 10:41 AM   #476
TINK OP
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OIL LIGHT ON ! ! ! Danger Will Robinson!

WTF

Got PROJECT-S all buttoned up. Started her up, All system good to go. Ride down to the gas station, throw a couple of gallons of gas in her, hit the starter... the YELLOW light is on, WTF ! ! !

Two block home so I risk getting her there under power, YELLOW ligh goes out!?

Key off, restast, YELLOW light is ON again!

Off to Harbor Freight to get an oil pressure test gauge... stay tuned.

TINK
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Old 06-15-2013, 01:15 PM   #477
Kai Ju
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Ground the oil pressure switch connector and see if the light goes out. If it does, check that the connector is tight on the spade. Also check continuity through the switch, with the engine cranking.
All this after you check your oil level and oil leaks..
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Old 06-15-2013, 01:42 PM   #478
TINK OP
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What's "normal" oil pressure?

Checked the oil pressure and I get 60 psi at 4,000, THANK GOD!

What's the "normal" oil pressure suppose to be?

All I can find is the pressure for the switch which is something like 3 to 8 psi.

Suspect the oil pressure switch, trip to Irv Seaver's for a new switch.

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Old 06-15-2013, 01:45 PM   #479
TINK OP
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Quote:
Originally Posted by Kai Ju View Post
Ground the oil pressure switch connector and see if the light goes out. If it does, check that the connector is tight on the spade. Also check continuity through the switch, with the engine cranking.
All this after you check your oil level and oil leaks..
Skipped a few steps Kai Jui and went straight for the oil pressure gauge.
Yes, I did check the oil level and after my brief ride to the gas station looked for leaks and found none.

TINK
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Old 06-15-2013, 02:32 PM   #480
DoktorT
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Quote:
Originally Posted by TINK View Post
The neutral switch connectors are a real PITA to plug in once the transmission is in place.
wouldn't ya know it, S N A P the connector breaks off from the switch.

Trans install, NO PROBLEM now with neutral switch sub-harness


Done!


TINK

I got 20 years in engineering, 15 years Euro shop background, and yet I as well ended up breaking that danged term. Your harness is a no brainer for resolving this issue. I will make that change next time I am in there.

Good one to post to the Tips and Tricks thread.
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