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luca.stere
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Hi guys,

I will start to rebuild a BMW R45 for a friend of mine. It will not be a restoration but I think it will be a nice BMW R45 with an older look, something like from the '50 (wheels with spokes, retro headlight, maybe another fender on the back). I hope you will enjoy it!

This is the frame, It is prepaired for painting:

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2valve
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Glen Innes N.S.W Australia
Joined: 04/05/2007
Posts: 173
Hi

Looks like the fun in the garage begins .I'm intrigued with the garage your working in , is that a service bay ? or is it a safety bunker (picture three) under the house/shed as i can see a ladder going down Thinking .How did the frame go with the paint job , still kept it black?.

luca.stere
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It's a small service bay

It's a small service bay where I am working when I have some time. I will paint the frame in black.

luca.stere
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And the frame is painted:

And the frame is painted:

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2valve
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Glen Innes N.S.W Australia
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Nice job

Service bays, bring back memory's for me climbing up and down on those slippery steps.Paint job looks pretty good, your not painting the swingarm /battery frame?.

luca.stere
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For the moment I don't have

For the moment I don't have the battery frame and the swingarm, but soon I will have them and I will paint also this parts.

luca.stere
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This is the engine, my friend

This is the engine, my friend told me is in good shape but I have to start the engine in order to see how is running:

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2valve
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Glen Innes N.S.W Australia
Joined: 04/05/2007
Posts: 173
Hi

Sorry for the late reply. How goes the rebuild ?. Looks like the engine is in need of your cleaning skills to match the new paint job, at'least your in the right workshop to get stuck into cleaning it and not worrying about making a mess at home. Is it a R100 motor/ 70HP ?. Is the R/H side head gasket blown ?.

luca.stere
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nothing important

2valve wrote:

Sorry for the late reply. How goes the rebuild ?.

Nothing important in this way, I was sick for a week and I have lost some time because of that. But now I am ok and I will start working again at this project.

2valve wrote:

Looks like the engine is in need of your cleaning skills to match the new paint job, at'least your in the right workshop to get stuck into cleaning it and not worrying about making a mess at home.

That is not a big problem for me, I have what I need in order to make the job done.

2valve wrote:

Is it a R100 motor/ 70HP ?. Is the R/H side head gasket blown ?.

Is a R45 engine, the gasket doesn't look blown but who knows... I have never seen this engine runing.

luca.stere
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So, I have continued with the

So, I have continued with the engine and I have found out that the engine electrics is a complete mess. A strange relay regulator was "attached" with a wood screw, a piece of cloth was used in order to insulate the electrics between relay wires and the diode assy (I believe is not original). The ignition control unit was from a VW/AUDI with soldered wires.

At least the starter is working: https://www.youtube.com/watch?v=gbL8Gl2dbdw&feature=youtu.be .

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2valve
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Glen Innes N.S.W Australia
Joined: 04/05/2007
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Hybrid engine

Well at'least the PO used components from european cars. If the parts still work OK , this will save you a small fortune on purchasing new electrics to run the bike .

luca.stere
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I will not keep

2valve wrote:

Well at'least the PO used components from european cars. If the parts still work OK , this will save you a small fortune on purchasing new electrics to run the bike .

I will not keep this parts, I can not trust them because they look crapy and I want to avoid problems. I can buy new aftermarket parts (not OE) for a good price. For exemple I can buy the ignition control module at 30$ and I am sure it will work just fine for the next 50.000km, maybe more.

I have cleaned the engine:

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luca.stere
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The engine looks clean inside

The engine looks clean inside at a first look. I have inspected the clutch and it's ok, the disk has 6mm thicknes (like a new one). I have found the paint signs on some parts and I have assembled the clutch with this signs at an angle of 120 degrees, exactly how it was before. I have tested the clutch with gearbox mounted and it works perfect.

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luca.stere
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I have disassembled the

I have disassembled the starter for inspection and cleaning. I was lucky and the starter just needed to be cleaned, works perfect.

  • starter
  • parts starter
  • cleaned parts starter
  • assembling
  • assembled starter
luca.stere
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The geneartor looks good, is

The geneartor looks good, is not fried and after the cleaning looks like a new one. I have to change the brushes.

  • generator
  • inside
  • cleaned generator
2valve
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Glen Innes N.S.W Australia
Joined: 04/05/2007
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Hi

Buddy your getting stuck into it.The old bike will be up and running soon the way your working on it. Would be a good idea to check the tension of both springs in the brush holder when fitting the new brush's, just in case one has soft tension.

luca.stere
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Yes

2valve wrote:

Buddy your getting stuck into it.The old bike will be up and running soon the way your working on it. Would be a good idea to check the tension of both springs in the brush holder when fitting the new brush's, just in case one has soft tension.

Yes, I hope until march 2016 it will be ready.

jphilipc
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VBMWMO #9029
Joined: 11/26/2015
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R45 questions

I'm new to this forum. I've had three airheads--a 1949 R50/2, a 1964 R60/2 and a 1968 R60US. I just bought a 1977 R80/7. I have never heard of an R45. What year was it built?

Also----All my older airheads were 6 volts and were kick start only.
My R80 is 12 volts and only electric start. Does this R45 have only an electyric starter?
Thanks,
Phil

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schrader7032
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Phil -Read about the R45

Phil -

Read about the R45 here:

http://www.bmbikes.co.uk/specpages/R45.htm

It should be very much like your R80/7 with twin shocks. It was also largely produced for the European market...I'm sure some floated to the US but that would be very few.

And is that R50/2 you have from 1949 or 1959?

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Kurt in S.A.
'78 R100/7 '69 R69S '52 R25/2

luca.stere
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From what

From what I know BMW R45 has only electric starter but I am not a BMW expert. If you want to verify something a good way to do that is to acces the www.realoem.com catalogue.

jphilipc
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VBMWMO #9029
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My old R50/2

Shrader--I owned the R50/2 from 1961 to About 1965. I thought it was a 1949 but can't be sure. It was cream colored. I built a luggage rack for it and rode it from Austin to Guadelajara and back. I loved it. On the straight road south of Saltillo I would ride it sidesaddle at 70mph, leaning back on my bedroll. They had a throttle lock then. I was lucky. Bugs are bad in Mex--hornets up your sleeve are no fun.

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schrader7032
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PhilC - They made the R50

PhilC -

They made the R50 from 1955 to 1960, then the R50/2 from 1961 to 1969...these are effectively model years. The only bike made in 1949 was the R24 (single cylinder)...it was the only bike that the Allies would let them build right after the war. Shortly after that, they began to build larger twin cylinder bikes. 1955 was a big model year as BMW came out with the full swinging rear suspension. Prior to that, the suspensions were called "plungers".

Any kind of bug at speed is no fun!!

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Kurt in S.A.
'78 R100/7 '69 R69S '52 R25/2

luca.stere
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I have found an original

I have found an original diode assy:

  • bmw airhead diode assy
  • bmw r45 diode assy
sminn560sl
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VBMWMO #7977
Central Kentucky
Joined: 04/13/2011
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R45

Good to see that you've putting another BMW back on the road. Looks like you're doing a great job of getting it together and running. I'm glad that you are correcting the electricals as I hate bodged systems like that.

From what I can see the engine looks great, with the exception of the external cosmetics. The valve train looked clean and well-oiled anyway. From the looks of it, it appears that this bike sat outside for some time.

Nice project anyway. Looking forward to seeing more updates.

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Steve in Kentucky
91 BMW K1 (caretaking); 87 BMW R80 (RS); 61 BMW R60/2; 66 BMW R27; 74 R90/6; 59 NSU Maxi; 71 Norton Commando; 71 BSA 250 GP; 66 Triumph TR6R; 61 Norton Manx; 59/61 Triton; 14 Triumph Thruxton

luca.stere
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I will try to do my best at

I will try to do my best at this bike, it will be a bike for long journeys and it has to be in a good shape.

The parts start arriving, I have now the rear drive, two rear shocks, the rear frame, the battery tray, two wheels, the sadle. But first I have to start the engine, I have buyed an oil filter and put new oil in the engine:

  • bmw airhed oil filter
luca.stere
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I have buyed new ignition

I have buyed new ignition wire (Beru) and spark plugs (NGK) and I have made new ignition wires:

  • NGK + Beru
  • BMW ignition wires
luca.stere
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The ignition sensor had the

The ignition sensor had the wires cut and without the plug, so I have extended the wires. Now, the electric part of the engine has returned to the normal condition as you can see in the pictures. Also, I have started the engine:

https://www.youtube.com/watch?v=BiBnIQmWMQQ

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luca.stere
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I have made some progress

I have made some progress since the last time I have written here. At a point this project was stopped but we have managed to start again. So, after I have painted the rear frame, battery tray an the swinging arm I have mounted the engine on the frame. New bolts for the transmission shaft fitted with Loctite.

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luca.stere
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At the rear drive I had a

At the rear drive I had a problem, the thread from the drain oil plug was ruined and I had to make another one. After that I have mounted the rear drive and I have tested some parts: rear wheel, shocks, exhausts, the tank.

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JDL
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Hi Luca, any updates on this

Hi Luca, any updates on this project?

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'55 R25/3, '80 R65, '01 R1100S

luca.stere
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Yes and no, this project has

Yes and no, this project has not been abandoned. I am sure that in the autumn I will advance further, for the moment I have some difficulties especially with the time because I am working also at other bikes (russian boxer bikes).

This is the bike now:

  • bmw_r45.jpg
luca.stere
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So, like I said before this

So, like I said before this project is not dead. Beside the free time problems I have encountered also another problems. I did not have a front fork and the owner did not want to buy an original one, I didn't understand why if we think he is a multiple BMW bikes owner.

Anyway, he decided to adapt a japanese fork (honda as I remember) and in order to do that I had to make a small project for the stem fork and asking to a turner to make the part:

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luca.stere
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New rubber

New rubber mount for the tank:

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