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808Airhead
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Here are some pictures of the

Here are some pictures of the almost completed bike!
First,here is the above mentioned tool in use

Bike coming together,front fender installed


Front wheel detail,I chromed the brake arms


I purchased a reproduction BMW speedo,however it was in kilometers,and just for fun bought a headlight restoration kit from S.Meyer,and I went ahead and installed the new (now glass instead of original plastic)lense,the only drawback was the tripmeter is now not able to reset since there is no hole for the tripmeter. This however does have the benefit of not having a way for water to leak into the speedo,like the original lense. I was so pleased how it came out that I used the original 33k speedo instead of the repro.

Here are pics of the restored headlight bucket,I used a screwdriver heated up with a electric heatgun to melt the tabs for the neutral & batt. light lense,it was tricky and I think the repro material was not as strong as the original and some "chunks" of plastic would break off if the heat was a little too high. It eventually worked out and the bucket is now together and on the bike,all that is left is to connect the wiring.

Original lense,repro ringf and reflector

Headlight installed with my "awesome" black rims Wink\

Here she is,basically a carb rebuild/cleaning,and wiring hookup needing to be done!

Pretty stoked,almost done only 1 year and a month to the day I drug her home!

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Thomas M.
R69s - R60/2 - R67/2 - R51/3

Darryl.Richman
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Surf City, USA (Santa Cruz, CA)
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Excellent work, it looks

Excellent work, it looks really great! Just wait until you fire her up the first time, you will be really thrilled!

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808Airhead
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Thanks Darryl! I am really

Thanks Darryl! I am really looking forward to riding it for the first time,my greatest fear is "unusual" engine noises!!

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Thomas M.
R69s - R60/2 - R67/2 - R51/3

jamesmoc
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Cork, Ireland
Joined: 09/18/2010
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That looks superb! i was also

That looks superb! i was also apprehensive at first starting my rebuilt R27 but it runs so much better/smoother than before I was amazed and hopefully yours will too. I'm sure you will have that unmovable smile on your face when you ride her down the road for the first time.

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808Airhead
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Hello everyone..........Here

Hello everyone..........Here are a couple of pics of one of the last operations before she is fully functional. I took a couple hours at my shop and with my home made rig,I baking soda blasted the carb bodies and using a new gasket set,proceeded to rebuild the carbs.
I was quite pleased that the baking soda blasting left a nice finish and was gentle enough for carb bodies and would not clog up any internal passages.
Jamesmoc.......thank you for the kind words,it is so true however,the last 5% of the rebuild is taking the longest!
Here are some pictures of carbs!

New idle screws from S.Meyer

The NOS slotted screws I found on ebay,and I blasted the 2 jet cover bolts as well

Here are the carbs in their "home" which they have missed for over a year now


How she stands,ALMOST ready to ride.

Aloha!

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Thomas M.
R69s - R60/2 - R67/2 - R51/3

808Airhead
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I updated this post with some

I updated this post with some carburetor restoration pictures,unfortunately they were "spam filtered". Hang in there and they should be up soon.

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Thomas M.
R69s - R60/2 - R67/2 - R51/3

mcdonnell7511
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New Mexico
Joined: 02/19/2009
Posts: 56
OEM

Thomas,
Nice decals!
Jack

808Airhead
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............you did a great

Wink ............you did a great job on those decals!

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Thomas M.
R69s - R60/2 - R67/2 - R51/3

mcdonnell7511
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New Mexico
Joined: 02/19/2009
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R69S

Ditto regarding your bike!

808Airhead
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Today,2/17/11 was a great

Today,2/17/11 was a great day,I finished up the last 2% of the actual build, which entailed getting the dry cell battery connections hooked up with a inline 10 amp fuse,then installing the horn as well as putting in the tail light bezel screw.
I got very lucky with the tail light bezel screw,since I did a last electrical check I noticed there was no screw holding the tail light
bezel to the fender,and was going to ride the bike for the first time today and it would have been a bummer to have the whole tail light assembly falling off at speed!!
After dodging a small bullet I was ready to ride it for the first time! I had started it and let it run for a few minutes while checking things,and this was repeated a few times,never letting it run more than
3-5 minutes at a time. This allowed it to heat cycle enough to re-torque the heads and adjust the valves. The exhaust tighened up a .001" or so,the intake was the same .006",and with a quick idle adjustment I was ready,the time had come........
After running a pre-flight check,I fired it up and this bike always starts up very well so far,and within 1-2 kicks she popped into life,with a mechanical symphony which was music to my ears,which was now real,instead of all of the imaginary visions I have been daydreaming about since I started on this journey. I had been dreaming of this day for over a year,and here it was,about to happen,it is a anxious,as well as joyous time,since it could be a very good day,a small personal triumph,or a day of wondering "what that knocking/grinding noise could be",and tearing it all back apart again.........
I roll it out of my garage,click it into gear,and the neutral light turns off,so far,so good,and let out the clutch and it is quite a rush to be riding this bike for the first time,and it is utter joy.
The bike has a very noticable power advantage over my R 60/2,and drove very tight & straight,and the transmission,final drive,engine are all doing thier thing with no oil leaks,and and no unusual noises ............THANK YOU,MOTORCYCLE GODS!
It was quite a relief to have everything working well,however into a 10 minute ride I would let off the gas and it would die out.
I put this down to carb adjustment and turned the idle screws up,and adjusted the mixture. It seemed Ok,althought the bottom end started feeling soft,and it would still die out intermittently. When I get back to the garage I proceed to adjust the carbs and it would keep dying out. I pulled a plug and they were black-ish. I then opened the gas cap and it made a "phoosh" sound when it was relieving pressure,which never happened on my other bike.
I put the cap on,thinking nothing of it and ran it again and it did the same thing,and when I opened the gas cap,it had the same pressure release sound,and realised that the gas tank was building pressure and forcing its way to the carb jets thereby flooding out my bike!
This was a repro gas cap from S.Meyer,Germany and had the little ripples under the cap for venting,however I had to drill a small 1mm hole and now the idle is rock solid and not as much fuel leaks out of teh floats after turning off the bike as well as no more fuel pressure in the tank!
You woud think a gas tank would make vacuum from fuel draining out into the carbs,however the "sloshing" of gas makes it expand,and actually was causing a pressure buildup due to no tank vent.
The only way I could prove this is to tell you to shake a small gas can lightly,then open it up and it will have pressure inside!
Aloha!

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Thomas M.
R69s - R60/2 - R67/2 - R51/3

schrader7032
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San Antonio, TX
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What an experience that must

What an experience that must have been! And pretty satisfying after all that work. About 5 years after my rebuild, I'm still amazed that I don't hear those awful grinding or knocking sounds, but I'm starting to let that go and just accept it as it is and that maybe, just maybe, I didn't "eff-up".

As to the gas tank pressure, when I was first reading your post, I said how could it be building pressure...it should be building a vacuum as you suggest. Of course, the fuel decrease is really pretty gradual when you think about it and with just about any venting or small air leaks, that vacuum would be offset by air seeping back in. But your situation still sounds unusual. I don't recall reading anyone mention that their tank built pressure. I could see that heat could do that, especially in a situation where there was a lot of trapped heat like behind a fully enclosed fairing or maybe due to extreme outside temperatures...hmmm, you do live in in Hawaii Big Grin But if you have the cause and effect figured out without a solution, there's only one thing to do...ride!!

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

R60 Sweden
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Congrats!!!

Waiting to feel like you ( Ihope for the mercy of the gods of mc, too!) when the r60 is rolling out. At the moment I have to get stuff inside as the garage really is a little cold in this -25 celsius cold. And my wife appreciate it, well, not fully!

But I'll have it running this year.

Interesting little story about the gastank...

loftus7608
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Joined: 09/01/2009
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Congrats Thomas!!

Nice job getting her out of the garage and onto the street. Happy riding! It must be very satisfying after all those months. And it is amazing how these bikes will start right back up after all its been through!

808Airhead
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Kurt,I agree with you,it is

Kurt,I agree with you,it is probably heat, causing the pressure,and yes,I am glad nothing is "effed up".......haha
R60 Sweden,I know something your wife will TRULY appreciate and you can also get some work done on the bike.
Simply move the bike into the kitchen or living room,OR bedroom if your wife is really nice.
If she protests,simply tell her,"this is how bikers work on their bikes,if it is good enough for the Hells Angels,it's good enough for us honey." Wives fall for it all the time.
You can thank me later.......
Loftus, I am glad you can understand the excitement of bringing something back to life and hearing it run for the first time,it really is like "mechanical birth",very cool to see a machine doing what it was designed to do (ride),vs. sitting in a dilapidated state waiting for rescue.......or the scrap heap......
I have this funny thought about the Karma of the machines that "come our way",and think "wow,how lucky is this machine?,to come into the hands of a thoughtful owner,instead of someone that would destroy it,like many others have been." Someone could have sold this bike for parts,or,who knows?
It is a great feeling to have rescued this mechanical work of art known as the "BMW R69s,the worlds finest motorcycle"
and a even better feeling when I ride it.
Hope this is some inspiration for some,finish those projects,summer will be here before you know it! Aloha

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Thomas M.
R69s - R60/2 - R67/2 - R51/3

privateer
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Great job on the build 808 !

Great job on the build 808 ! im about two months behind you on the build on my R50 so your thread is a great inspiration to me. Installing the bottom end next week (the wife had a confused look when i told her i need to drag her oven into the shop for a day or so).

808Airhead
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Good luck with the completion

Good luck with the completion of your project! I stuck mine right in the oven and thankfully it was grease free,so there was no smell!

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Thomas M.
R69s - R60/2 - R67/2 - R51/3

R60 Sweden
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Great, thanks for the tip!

I'll start to lug in the engine right this moment! She's not home so it'll be like a surprise when she's back!!!

Darryl.Richman
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A surprise, indeed!

R60 Sweden wrote:

I'll start to lug in the engine right this moment! She's not home so it'll be like a surprise when she's back!!!

Rolling On The Floor Rolling On The Floor Rolling On The Floor Laughing Laughing

I hope your wife has the same kind of sense of humor you seem to have!

(BTW, it's possible to do this job with a propane torch in the garage.)

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808Airhead
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Update.......135 miles on

Update.......135 miles on here so far so good except..........a couple of times i had hard starting when hot,and I attributed this to not turning off the petcock before I killed the ignition. If I would turn off the fuel and let it run for almost a minute,then restart it,it would start fine.
However a couple of times afterward I got a NO START,I mean,kicking it 20+ times and nothing..... I went for a 20 ile ride and 2.5 miles from home she dide out at a traffic light and would not start.I had to wait for 1.5 hours ad then like magic,she started!!
I blamed this on the original coil that appeared in perfect condition,and worked fine at first.......
I installed my "Emerald Isle"/Benchmarkworks repro coil and she now has a smoother idle and faster startup,so I am hoping this will cure my hot start issues!! Wish me luck!

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Thomas M.
R69s - R60/2 - R67/2 - R51/3

schrader7032
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San Antonio, TX
Joined: 10/27/2006
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Good luck on the hot

Good luck on the hot starting! I had similar situations...one time I had to wait 30 minutes at a gas station before I could restart. Even after getting Vech's coil, I was still unsure of my self during hot starting. But I found that I really had to alter my technique hot versus cold. When cold, it seems to really need to be tickled and made "rich". But when hot, I have to do everything I can to avoid flooding it, so like you, I attempt to turn off the petcock ahead of time, don't touch the petcock until she's starts, and repeated kick through with a wide open throttle to really clear the combustion chamber of fumes. Then I leave my had off the throttle, push the key on, and give a good kick...usually one kick is all it takes. I might have to baby the throttle a little, but it usually will run fine and then I can turn on the petcock. Oh, and don't wait until you're a half mile down the road to remember the petcock!! DAMHIK.

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

Darryl.Richman
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Surf City, USA (Santa Cruz, CA)
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That is the classic symptom

That is the classic symptom of a coil headed south. When I first got my R51/3, it started easy, but if you had to stop it, it would take a solid hour to cool off enough to start again. And it had a tendency to die when hot, and coming down to an idle.

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808Airhead
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Well,it has been a year since

Well,it has been a year since I have finished this bike,it has been driven 1393 miles so far,and performed beautifully. I had only 1 small issue recently and that was with my original 40+ year old brass floats. They developed a crack from age/vibration. I replaced them with some new brass Bing ones,and the bike has been a dream!
I will soon have time and do my first major servie on the bike at 2K miles. Enjoy your Bikes!

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Thomas M.
R69s - R60/2 - R67/2 - R51/3

Dominic
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Bullaburra Australia
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Looks Fantastic, great

Looks Fantastic, great looking rebuild!

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Dominic
1968 R69US
1973 R75/5
1971 Norton

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