Airhead cafe racer project

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BaconPopTart

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Hey guys just thought some of you may like to follow this, Im already into the build so excuse the photos as they were not taken with consideration to be shown on a forum.
Due to getting a date for a long awaited shoulder operation I sold my sv650 as I wont be able to get out over the coming summer due to the healing time.
So with some cash in my pocket at the start of March I bought a 1980 R45 BMW..... yes its a 45 but hey I got it for a steal of a price and the bike is in real good condition I'd be happy to say its sat in some old boys garage for many a year.

The day I bought it.

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And the minute I got it home, took it down to the frame and inspected everything properly just to make sure it was in in order.

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Still had the pump fitted. Can only imagine how long youd be at it to even get it ridable.

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So basically I had started removing things I don't want or need.
I have been extremely careful to unbolt everything label it and box it so nothing is getting cut up and wasted.
If for some reason I want to put the bike back to original then ill have all the bits.

At this point I then underwent the surgery Ive been waiting on for the last 2 years from multiple downhill incidents.

So progress will be slow for a while as I am literally doing everything 1 handed but I will up date regularly.
 

BaconPopTart

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BaconPopTart
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Over the hill and down the road
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Up to date
The bike wasn't ticking over properly and revving up randomly which only started happening after the 50 mile ride home. So we had a bit of a tinker with it and it's better... I have no clue about carbs really as they are long before my time haha but i'm learning.
Unfortunately while out testing the adjustments a seal on the back of the box went and most the engine oil was lost. I noticed before any damage was done and got it home safe so it looks like the bike will be getting a full rebuild as most the seals look to be the original 1's.

Removed the mudguards and tail section as well as the crash bars.

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I'm cheating a little bit and having a subframe made for me (Still only got 1 working arm) so i've been concentrating on the front end currently.

New headlight bracket allowing me to tidy the front end and small LED blinkers.

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At this point I then decided to lower the front end down. Removed the rev counter and the extremely basic instrument cluster to leave just a speedo.

And of course fit clip ons.

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So this is how it looks now awaiting my subframe arriving.

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Any CC are welcome, i've been riding bikes since a very young age and my father has always had bikes but this is my first build,,, he thinks I am ruining a perfectly good bike and wants nothing to do with it.
 

fabiostar

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i was about to say thats to good to go chopping up to make a cafe racer but then i read your unbolting instead of getting the angle grinder out..keep the pics comming its nice to see somebody do mods to older stuff like this(y).

and get a pair of carb rebuilt kits, im sure yours will need it after all these years.
 

Setzer

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92
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Lisburn/Dunmurry
I had an R65 for a good few years and loved it as it was totally reliable, I eventually sold it with about 400K on it still running well!

The carbs on these are prone to getting water in them, just unclip the wire retainer at the bottom of the bowl, take it off and tip the water out, it's a 2 minute job to do both carbs.

I'm going to follow this thread to see if your dad is right lol.
 

dannydnn

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865
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downpatrick
There's a rougher one of these I see knocking about all the time that's put one on the to own list after I do my direct access next month

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Apis

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If you haven't already made your mind up about definitely doing a cafe racer, have a good search on Pinterest for brat or tracker style airheads.

Not saying I think they look cooler than cafe racers, and it's not my bike, but .......
 

Dave..

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10,037
Lovely looking BMW, you must be a young lad to use those clip on's? :laughing:
My back is busted from drop bars on RD 250 and 400's :sob:
 

BaconPopTart

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BaconPopTart
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Over the hill and down the road
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Full Fleet
@stuarty7
Im pretty sure I followed the build on this on rms??

Im not as young as I'd like to be haha early 20's finishing final year of uni in May... All so seeing the consultant on 5th may so hopefully I get the all clear to tear away at the bike.

Next step is to start and build myself a seat so hopefully Ill get some pictures and updates up soon. After May I can dedicate a lot more time to the project so dont be disappointed with slow updates for the next few weeks.
 

stuarty7

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ballywalter
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accord type s
@stuarty7
Im pretty sure I followed the build on this on rms??

Im not as young as I'd like to be haha early 20's finishing final year of uni in May... All so seeing the consultant on 5th may so hopefully I get the all clear to tear away at the bike.

Next step is to start and build myself a seat so hopefully Ill get some pictures and updates up soon. After May I can dedicate a lot more time to the project so dont be disappointed with slow updates for the next few weeks.

Yes that's the one think I'm going to sell it now quite tight for space atm
 

BaconPopTart

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BaconPopTart
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Decided to have a fiddle with the carbs to see if they were in fact dirty/ water logged etcetc...

At this point ill be honest, I have no idea what i'm looking for other than the basics when I dropped the bowl off each side they looked fairly ok to me. no water and just a bit of silt at the bottom but I gave them a good clean out anyway and a blast with the air line.


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Seem to be ok to me?

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Gaskets how ever are definitely done!

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So then I decided that I would remove the carbs completely. Every single screw/ bolt is seized rightly and at this point I just want to undo everything to look inside but I suppose I may learn properly about them as i'm sure it wont be the last time I have to look at them.



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Very minor update again, next in line is the throttle as the twin cable set up sucks and it doesn't flick back at all nor does it do much when you twist it back to rev the engine. Between carbs and throttle lies my problem of the bike not running correctly and revving itself up at this point i'm now leaning towards the cables.
 

BaconPopTart

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BaconPopTart
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check the inlet rubbers for cracks aswell, when they old they tend to harden and leak air and as stupid as it sounds make sure the floats actually float, they can get pin holes in them ,

All the black tubing, from air box to carb and carb to heads are completely dosed and cracked I have new 1's ordered.

And the floats do float however 1 of the left hand side 1's was bent massively out of shape (the metal bracket) so I've carefully corrected it.
 

fabiostar

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just over there.
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the floats will need set straight as you have done, the rubbers between the carbs and the engine are the ones that cause problems. if theres air leaks when you shut the throttle it will make the engine hang onto revs. change the cables cause god knows how old they are. they are Bing carbs on that bike i take it?.
 

Apis

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Yeah, change the cables, or they might just need oiling, which can make quite a difference.
If you're changing them, then Teflon ones are worth looking out for. (But don't oil them). The likes of motobins, Sherlock or Motorworks do them.
 

BaconPopTart

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BaconPopTart
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Yeah, Bing carbs... Good or bad? Haha
And yeah new cables ASAP.

Have the exhausts off now unsure if I'm going to hollow the end cans or buy nice slip ons, @stuarty7 's yoshi really does it for me so I may have to splash out.
 

fabiostar

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970
Location
just over there.
Drives
...........
Yeah, Bing carbs... Good or bad? Haha
And yeah new cables ASAP.

Have the exhausts off now unsure if I'm going to hollow the end cans or buy nice slip ons, @stuarty7 's yoshi really does it for me so I may have to splash out.

i wouldnt say good or bad just getting on in years lol.. make sure the diaphrams at the top dont have any pin holes in but go carefull with them they rip easy. aaahhhhhh dont butcher the pipes, take them of and buy slipons.
 

BaconPopTart

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BaconPopTart
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Over the hill and down the road
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Full Fleet
i wouldnt say good or bad just getting on in years lol.. make sure the diaphrams at the top dont have any pin holes in but go carefull with them they rip easy. aaahhhhhh dont butcher the pipes, take them of and buy slipons.

I cant for the life of me open the top up. They are completely stuck closed and its just a very shallow flat head to undo which I dont want to wreck.

The inlet rubbers on both sides are in pretty bad shape.

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Couldnt be doing any good. These are between the carb and the heads.
 

BaconPopTart

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BaconPopTart
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Over the hill and down the road
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Full Fleet
So last night I had the exhausts off in preparation to wrap them with heat wrap, I all so done a magnificent job of bodging the speedo with a bracket all ready in place on the bike.

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And how it looks on. I managed to do this alone. If i do it again I will be sure to use water as the amount of fiber glass in me is painful. I have the ignition disconnected and cant start the bike so I didnt want them sitting wet for how ever long.

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This doesnt look tidy but it doesnt bother me at the moment. I will fix it up when the time comes.

The bracket is for the front brake line and just happened to be in a good position with a hole in it in the right place.

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Speedo has 2 small threaded studs on the side of it....

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Magic.

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I now all so have mirrors

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The inner brace/ bracket of the original front mudguard un-bolts which makes for a nice little front guard. Gave it a quick sand and a lick of gloss black just to get an idea, might just use some filler to make it all flat and run it for the mean time too as it doesnt look too bad.

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On an other note I am starting to get very annoyed that my sub frame still hasn't been sent. I ordered it close to 2 months ago and I have been in contact with the company who keep telling me it is a hand made 1 off bespoke item and it takes time.
Its literally 5 bits of metal welded together.....
Only reason I ordered 1 was because of my arm situation thinking that as my arm got better i'd already have it fitted and could work on making my own seat unit.




POV is very enjoyable all the same. Cant wait to get out on it!!!

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BaconPopTart

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BaconPopTart
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Over the hill and down the road
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Full Fleet
Been a busy week, alot of uni work had to be done.... consultant said my arm is well on the mend and im now allowed to use it again so thats a plus!

Few more things done to the bike so more pictures for you all.

First of all I have taken the wheels off front and back and painted them black. Please excuse the over-spray on the tyres. I need new tyres anyway as the current 1's are well dosed. it has changed the look of the bike alot which i am really liking.

This all so gave me a chance to clean out the rear brake drum... Asbestos 101

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Baking in the sun :cool:

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Carb rebuild kit came from moto-bins. Next day delivery, top job.

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As seen with lots of previous bits like the bowl gaskets and the silicone hoses for example were beyond any use for the bike many of the O rings in the carbs are the same.

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Bottom half are all built up again and nice and fresh. Having problems taking the tops off to change the diaphragms. Which going by the rest of the carbs they will 100% need changed.
Going to try heat and if not then i'll just drill them out.

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So in the mean time ive taken the sub frame off in preparation for my still non-existent new sub frame that I ordered 2 months ago.

At this point the bike is looking very much like a bobber and i love it! Unfortunately the angle of the drive shaft is causing it to fowl on itself and it doesnt roll hence the wheelie board.
Ive mocked up a little bracket to allow me to re angle the engine block so that I can run it this low as a bobber. Plan is to contact the guy doing the sub frame on Monday and if there is no sign of it then it might become a bobber as apposed to a cafe racer.

Time will tell.

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This week should see a lot of needed items turn up.
New silicone hoses
Torque trumpets for the exhaust as im planning on running just the straight pipes.
My rear sets
New front brake lever and resi with matching clucth lever
New grips
New throttle.
And associated cables.
Once this all arrives I will get the ignition barrel mounted and re wire the loom. All that will be missing will be the rear brake light but at least ill be able to fire the bike up again..... Hopefully.
 
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