85 RS restoration (part #1)

Oldgoat · **351** Re: 85 RS restoration (part #1) Tue Jul 05, 2011 2:50 pm

Oldgoat

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Thanks guys! Had to work yesterday so no more progress. Sad

OG

Oldgoat · **352** Re: 85 RS restoration (part #1) Tue Jul 05, 2011 2:51 pm

Oldgoat

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Hey Geordnz,
Here is the relay box ID sheet from the downloads page.

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geordnz · **353** Re: 85 RS restoration (part #1) Wed Jul 06, 2011 5:25 am

geordnz

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Ahh, thanks for that OG. Seen this some time in the past. The ani theft connector looks very like the fuel tank plug. I'll keep a note of that if ever I need one! I still wonder what "special equipment" is?

club_c · **354** Re: 85 RS restoration (part #1) Wed Jul 06, 2011 8:55 pm

club_c

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special equip=heated grips

geordnz · **355** Re: 85 RS restoration (part #1) Thu Jul 07, 2011 6:14 am

geordnz

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OH, Thanks club_c. That's a bit dissapointing.. I was hoping for something more ... 007'sh LOL. Cheers

Oldgoat · **356** Re: 85 RS restoration (part #1) Fri Jul 08, 2011 1:59 pm

Oldgoat

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fluids going in today....

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OG

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club_c · **357** Re: 85 RS restoration (part #1) Fri Jul 08, 2011 4:42 pm

club_c

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somebody likes Amsoil...

Oldgoat · **358** Re: 85 RS restoration (part #1) Fri Jul 08, 2011 4:59 pm

Oldgoat

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Yeah, C guilty. Smile

Oldgoat · **359** Re: 85 RS restoration (part #1) Fri Jul 08, 2011 5:01 pm

Oldgoat

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Cleaning up the gauges and have an e-mail off to autoillumination to determine what the options are for LED replacement. Also, need to cut a hole in the panel as I got it off flea-bay without the hole.

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OG

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charlie99 · **360** Re: 85 RS restoration (part #1) Fri Jul 08, 2011 6:57 pm

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good one og .......i was relieved when i saw dot 4 on that brake fluid ....

Oldgoat · **361** Re: 85 RS restoration (part #1) Fri Jul 08, 2011 7:08 pm

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Hey mate. I just heard from Tracy and the bulb we need is a Ba7s and here is the link: http://autolumination.com/74.htm

OG

charlie99 · **362** Re: 85 RS restoration (part #1) Fri Jul 08, 2011 7:32 pm

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yay !!! great find og .....

im going to have to get an order together i think..

i like the idea of the inverted lenses ...but i havent seen the super wide leds work yet .....hmmm maybe both and report on what i find ?

would have been great for the 1 watt leds ....but thats for a different base ...

Oldgoat · **363** Re: 85 RS restoration (part #1) Fri Jul 08, 2011 7:35 pm

Oldgoat

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Yep, mate I just put in an order for the inverted so lets keep each other posted on results.

OG

robmack · **364** Re: 85 RS restoration (part #1) Fri Jul 08, 2011 9:37 pm

robmack

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2" hole saw with a tiny bit of filing works perfectly. Been there-done that.

I think the LED equivalent of the bulb you've phtographed is:
http://www.superbrightleds.com/cgi-bin/store/index.cgi?action=DispPage&category=755&Page2Disp=%2Fspecs%2Fba7s.htm

I received something similar to this in the LED kit that I bought for my instrument cluster.

charlie99 · **365** Re: 85 RS restoration (part #1) Fri Jul 08, 2011 10:00 pm

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nice one rob ....

Oldgoat · **366** Re: 85 RS restoration (part #1) Fri Jul 08, 2011 10:39 pm

Oldgoat

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Nice Rob! I was going to make a template and use my dremel router bit, but the hole saw is gonna be soo much faster. Very Happy

Maybe five minutes including the sanding. Thanks again buddy!!
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Oldgoat · **367** Re: 85 RS restoration (part #1) Sun Jul 10, 2011 1:29 pm

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Hit a few roads blocks during assembly of everything. Looks like I got the wrong throttle cable and will need to do a little grinding and the pump cover isn't sealing and may have to go to the machine shop...

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OG

Oldgoat · **368** Re: 85 RS restoration (part #1) Sun Jul 10, 2011 1:43 pm

Oldgoat

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Got the rest of the plug and play wiring additions done for the gauges and the hazard switch. New tank rubbers arrived and lubed up this time. Thanks Charlie!

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OG

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charlie99 · **369** Re: 85 RS restoration (part #1) Sun Jul 10, 2011 1:52 pm

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dang that pump cover og .... hadnt thought to resurface it with wet and dry on a pane of glass or a nice tile ?

looking sweet mate !!!!

Oldgoat · **370** Re: 85 RS restoration (part #1) Sun Jul 10, 2011 1:59 pm

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Yeah, mate I did the paper and glass thing and still no joy. Sad

I'm thinking at this point that the pump housing may be out of spec so obviously it would have to come off and I'd have it done at a local shop. One last attempt last night with the ten step sealing process and I've got about 12hrs left in the 24hr cure cycle and will shall see.

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Oldgoat · **371** Re: 85 RS restoration (part #1) Sun Jul 10, 2011 2:02 pm

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I'm thinking while I wait it would be a good time to finish the instrument cluster and my gauge LED's are on the way so good time to get it all done at once. Smile

OG

BIG D · **372** Re: 85 RS restoration (part #1) Sun Jul 10, 2011 4:32 pm

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Its all coming on swell OG I like this LED concept especialy the idea of one replacing the side light that I must do.

BIG D

Oldgoat · **373** Re: 85 RS restoration (part #1) Sun Jul 10, 2011 5:58 pm

Oldgoat

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Thanks Big D! She is certainly keeping me busy, lol! I think it was actually K-Bike who got me interested in updating cluster & gauges with a great write-up he did a while back.

OG

Oldgoat · **374** Re: 85 RS restoration (part #1) Sun Jul 10, 2011 6:34 pm

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A wee bit of file work and my throttle cable dropped right in. You would think by this time I would remember to double check all aftermarket sources to insure they are compatible with the early Mk I's. Embarassed

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chrish8846 · **375** Re: 85 RS restoration (part #1) Sun Jul 10, 2011 7:03 pm

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It's all just so damn clean,I'm envious

robmack · **376** Re: 85 RS restoration (part #1) Sun Jul 10, 2011 11:20 pm

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It's not as clean as OG would have you believe. I noticed METAL FILINGS under his vice!!! FOR SHAME!!!! Very Happy

Kidding aside, that bike is going to be phenominal.

geordnz · **377** Re: 85 RS restoration (part #1) Mon Jul 11, 2011 2:52 am

geordnz

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Puts mine to shame, covered in cow shit at the moment after the weekends rides, I've cleaned the boots, now for the bike! Lol

pjjms · **378** Re: 85 RS restoration (part #1) Mon Jul 11, 2011 3:17 am

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Stunning. I doubt you could buy a new bike that good. Great work.

charlie99 · **379** Re: 85 RS restoration (part #1) Mon Jul 11, 2011 4:50 am

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lol true geord ...mines covered in gray stuff from ripped up roads.....and does it get into every thing .......omg ....giggles

blaKey · **380** Re: 85 RS restoration (part #1) Mon Jul 11, 2011 6:09 am

blaKey

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Hey Oldgoat...if mine looked as clean as yours, I wouldn't ride it!

Well done mate!

Oldgoat · **381** Re: 85 RS restoration (part #1) Mon Jul 11, 2011 2:50 pm

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Thanks guys! You know how it gets when you forget to take your OCD meds. Wink

OG

Oldgoat · **382** Re: 85 RS restoration (part #1) Mon Jul 11, 2011 4:29 pm

Oldgoat

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still no joy on the pump cover. Sad

looks like I'm going to have to address the pump housing after all.

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Oldgoat · **383** Re: 85 RS restoration (part #1) Tue Jul 12, 2011 12:07 am

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Hey Guys,

Tips and/or tricks for getting the plenum box back over the throttle bodies please? Does it help to pull the fan motor to have more room to rotate the box over onto the bodies?

Thanks,
OG

Guest · **384** Re: 85 RS restoration (part #1) Tue Jul 12, 2011 1:26 am

Guest

Blood, sweat and tears, mate. Oh, and sheer subtle force worked for me.
No need to remove the fan. I think I used a swab of silicon spray wiped round the inside of 'em with my clean fingertip too.

walfish · **385** Re: 85 RS restoration (part #1) Tue Jul 12, 2011 2:37 am

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OG - i did my pump late last year and had a similar problem, i made up a gasket from a roll of brown paper(160 gsm) very thin, this together with sealant solved the problem, you could try standard A4 print paper which is a bit thicker but can still do the trick.
i picked this up from my dad who was an old time car mechanic.
I sometimes work in central London and across the road in a apartment the tenant has a fully chromed HD in the window which is admired by all, when completed your bike could easily replace it.
as the aussie's say - goodonya

Guest · **386** Re: 85 RS restoration (part #1) Tue Jul 12, 2011 5:29 am

Guest

That would be nice to see as you passed by everyday on the way to work or the shops, but what sacrilege to have a BMW that no one would ever hear running!

Oldgoat · **387** Re: 85 RS restoration (part #1) Tue Jul 12, 2011 11:36 am

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Thanks guys! I was afraid you were going to say that twb. I definitely was uttering some well chosen expletives in the garage last night, lol!

Great tip Ungaas and I'm thinking I will see what McMaster's has in gasket sheets before I pull the body and go thru all that again.

OG

club_c · **388** Re: 85 RS restoration (part #1) Tue Jul 12, 2011 12:15 pm

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Regarding the TB's, as TWB said, some lube on the sleeves and TB's themselves eases the install. Make sure the clamps are ultra loose to allow for the stretching rubber. Biggest trick is to get them on top of the sleeves below the upper frame rail. Once there, you can begin to force/wiggle one side in, and then the next one, and the next and 'pop', they finish off. Just really make sure the lower sleeves are well sealed to the head with a hi temp sealant, or you will get very good at re and re-ing that intake plenum. Ask me how I know (re and re 5X).

walfish · **389** Re: 85 RS restoration (part #1) Tue Jul 12, 2011 1:41 pm

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Oh yes, it is sacrilege to see a bike stuck up in a window, the apartment is bang in the middle of Knightsbridge and must cost a few mill. (a apartment across the road recently sold for 22mill.) so a HD at 10k is small change to the excessively rich,without conscience.

OG check with a vernier the thickness of the paper, you want a thickness of 0.08mm or 3 thou.imperial, this wont affect the performance of the pump, or hasn't mine.

Oldgoat · **390** Re: 85 RS restoration (part #1) Tue Jul 12, 2011 1:49 pm

Oldgoat

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Hey Ungaas,
Just found this at McMaster-Carr and looks like they have several thickness choices. Is thinner going to be better?

http://www.mcmaster.com/#paper-gasket-sheets/=d59b7n

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Oldgoat · **391** Re: 85 RS restoration (part #1) Tue Jul 12, 2011 2:05 pm

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Thanks for the finer details C! My plenum box is so tight up against the frame it rubbed thru part of the main loom and last night after a long day was not the time to try and get it in. Smile

OG

walfish · **392** Re: 85 RS restoration (part #1) Tue Jul 12, 2011 3:40 pm

walfish

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OG that looks way too thick, I used ordinary brown paper the stuff that kids use to wrap their schoolbooks, or try some inkjet printer paper, you don't want to go too thick. give it a go, costs nothing and puts the bike on the road.

club_c · **393** Re: 85 RS restoration (part #1) Tue Jul 12, 2011 5:00 pm

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Oldgoat wrote:Thanks for the finer details C! My plenum box is so tight up against the frame it rubbed thru part of the main loom and last night after a long day was not the time to try and get it in.

OG

Yup, its a very tight fit...

chrish8846 · **394** Re: 85 RS restoration (part #1) Tue Jul 12, 2011 9:47 pm

chrish8846

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I pulled my fan and used a pry bar on the top of the plenum box and it finally popped in, I also lubed the inside of the tubes with vasoline.

Oldgoat · **395** Re: 85 RS restoration (part #1) Tue Jul 12, 2011 9:55 pm

Oldgoat

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Yeah Chrish I was eyeing pulling the fan last night before I decided it was time to take a break and come back fresh. Did you intall the rubber boots on the throttle bodies and than lever the box onto those?

OG

club_c · **396** Re: 85 RS restoration (part #1) Wed Jul 13, 2011 12:38 am

club_c

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FWIW OG I had the TB's assembled to the plenum and then pushed the whole mess onto the boots at the head.

Guest · **397** Re: 85 RS restoration (part #1) Wed Jul 13, 2011 4:48 am

Guest

I too did what Clubbie did, OG. It worked even though it was a bit of a struggle.

BIG D · **398** Re: 85 RS restoration (part #1) Wed Jul 13, 2011 7:37 am

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I used a light spray of silicone to fit mine slipped on a treat, All this talk of making gaskets reminded me of my Triumph Bonnie days and other brit bikes when we made gaskets from cornflake packets Very Happy

seriously though OG you are going to have one cool looking bike after all this, and this thread has been better than looking at an Haynes manual. Laughing

BIG D

Oldgoat · **399** Re: 85 RS restoration (part #1) Wed Jul 13, 2011 12:36 pm

Oldgoat

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Thanks for all the support guys! Smile

You all are a BIG reason why this project has remained enjoyable throughout the process.

OG

Oldgoat · **400** Re: 85 RS restoration (part #1) Thu Jul 14, 2011 7:14 pm

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LED's for the gauges arrived today. Smile

Will pop them in this evening and access how the inverted bulb works... Just out of the bag the output is much better than the OEM bulb. The LED is the bottom pic

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OG

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Oldgoat · **401** Re: 85 RS restoration (part #1) Thu Jul 14, 2011 7:22 pm

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Going to get the pump housing off this evening and have it lapped along with the cover and hopefully than I can finally fill her up and hit the button! Swiped some Hylomar from a buddy and really like the ease of assembly so I had to pick up some of my own!

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377 Re: 85 RS restoration (part #1) Mon Jul 11, 2011 2:52 am

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378 Re: 85 RS restoration (part #1) Mon Jul 11, 2011 3:17 am

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379 Re: 85 RS restoration (part #1) Mon Jul 11, 2011 4:50 am

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380 Re: 85 RS restoration (part #1) Mon Jul 11, 2011 6:09 am

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382 Re: 85 RS restoration (part #1) Mon Jul 11, 2011 4:29 pm

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383 Re: 85 RS restoration (part #1) Tue Jul 12, 2011 12:07 am

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384 Re: 85 RS restoration (part #1) Tue Jul 12, 2011 1:26 am

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385 Re: 85 RS restoration (part #1) Tue Jul 12, 2011 2:37 am

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386 Re: 85 RS restoration (part #1) Tue Jul 12, 2011 5:29 am

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388 Re: 85 RS restoration (part #1) Tue Jul 12, 2011 12:15 pm

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