1982 R100 "S" Service Log

Service Log

I'm keeping a log of all the service that I'm having done or doing to this motorcycle, and I figured I could keep it online just as easily. I have no idea if this will be helpful to anyone other than myself.

Date Mileage Service Mechanic/Location Notes

2001

Apr 17, 2001 Unknown (around 70,850) Pre-purchase inspection Marty's BMW (Los Angeles) Needs new: speedo cable boot, intake fittings. Found the rear rim is "slightly" bent, starter needs to be lubed. Right cylinder leaked 100% in a leakdown test (through the exhaust valve), left 12%. Right cylinder 100 psi in compression test, left 120. Stiff throttle cable.
I was personally not pleased with the apparent effort that went into the inspection, as they missed a really gummed up carb, and slipping clutch(!).

Apr 27-29, 2001 70,915 Post-purchase repairs Ian Johnston Replaced: throttle cable; speedo cable boot; petcocks; spark plug wires; floats; float pivot pins; float valves; fuel line; intake hose-stubs. Cleaned the carbs. Cleaned up and lubed the throttle chain cam and mechanism. Replaced the stock S mirrors with Napoleon bar-ends. Inspected the clutch adjustment (needs to be more thoroughly checked and possibly adjusted). Inspected the air filter, and vacuumed it out.

May 5, 2001 71,010 Clutch adjustment Cascade BMW Adjusted the clutch to see if it's really slipping, or just poorly adjusted. It's really slipping.

May 6, 2001 71,030 More post-purchase repair Ian Johnston Replaced the clutch cable (although the old one looked fine, so I saved it out) and choke cables. Cleaning out the choke lever housing on the handlebar produced amazing results -- it feels like brand new, clicks into position perfectly.

May 17, 2001 71,106 Clutch and input shaft seal replacement Cascade BMW Pretty standard, they also reported that the drive splines are 50% worn.

May 19, 2001 71,180 Tech day repairs Dave Cavanaugh, Kevin Beretta, Ian Johnston Re-welded the centerstand with new footpads (it was worn entirely through before), and added a tang. Balanced the carbeuretors.

Jun 1, 2001 71,311 Replaced left float bowl Ian Johnston Had to replace the whole float bowl just to replace the little starter jet/choke jet that's pressed into the bowl. Ah well, that one needed to be replaced anyway.

Jun 3, 2001 71,362 Relettered idiot lights, replaced indicator bulbs Ian Johnston Took off the instrument pod to replace the tach face light, and ended up replacing all the bulbs and the gasket. Also relettered the idiot light labels with enamel so I can read them again. Image of the renewed face here.

Jun 6, 2001 71,362 Replaced front brake pads, centerstand spacers, instrument lights, instrument light carrier Ian Johnston Replaced moderately worn stock front pads with new EBC pads, since I liked them so much on the K75. Replaced the centerstand spacers, since they were as much as 2mm out of true, resulting in the bike resting too far back on the stand. The light carrier and lights were replaced when I determined that the light contacts on the old carrier were well-corroded. Nice side benefit: the lights are noticably brighter now.

Jun 16, 2001 71,471 Adjusted valves and carb floats Ian Johnston Re-adjusted the valves to make sure they were set up right. If the PO really did adjust the valves before I got the bike, it's got severely receding valve seats -- both exhaust valves were tight. I suspect that he didn't adjust the valves, though, which means he lied about that service, as well as the changed compression readings. The reason I suspect that is that the valve covers were still glued on with gasket sealant, and he had mentioned having "sealed" the engine as part of preparing it for sale. The adjustment to the carb floats was to try and fix them dribbling gas on my boots as I ride; the fix didn't work though.

Jun 23, 2001 71,515 Replaced left float bowl again Ian Johnston Turns out the first new float bowl had a loose overflow tube, so it slowly seeped gasoline, dripped it onto the shifter pad, and thence onto my boot. Very smelly. BMW warranty-replaced it, and the new one is fine.

Jul 15, 2001 71,719 Changed engine oil and filter Ian Johnston Uneventful, unless you count two trips back to Ride West to exchange incorrect parts they had sold me. I'm sure they were honest mistakes, but it's frustrating to have a .5 hour oil change take a day and a half.

Aug 5, 2001 71,896 Replaced and rekeyed seat lock Ian Johnston The old seat lock rotated freely, making actually locking the seat a dicey affair. When I figured out that this was due to the lock body having been worn down, I decided to replace it, but getting a matched lock costs $50 vs. a generic for $23. So I rekeyed a generic. See the journal for more info.

Sep 9, 2001 72,025 Added Helicoil to final drive "level check" plug hole, changed oil in drive shaft and final drive, replaced turn signal bulb Ian Johnston and Autosport Seattle Removed final drive for Helicoil insertion after being unable to remove the "level check" plug. Repaired at Autosport Seattle. Refilled drive shaft and final drive with fresh oil.

Sep 15, 2001 72,090 Rebuilt carbeuretors, adjusted necessary valves Ian Johnston Replaced diaphragms and all the little O-rings trying to fix a rough idle. Adjusted the right exhaust valve, as it had tightened up to no clearance. (Watching for possible recession, since the valves were adjusted less than 1000 miles ago -- although I may have done it incorrectly last time, it's possible.)

Sep 29, 2001 72,159 Checked valve adjustment on the right cylinder Ian Johnston Exhaust valve was still right where it should be, at .15 mm. Had been worried it had closed up due to seat recession or incorrect adjustment, but all was fine.

Oct 16, 2001 72,312 Replaced final drive oil Ian Johnston Oil had indications of water contamination. Looking into why that might have been.

Oct 24, 2001 72,445 Refilled battery electrolyte Ian Johnston Not quite down to the plates.

Nov 1, 2001 72,554 Replaced both tires: ME33 front, ME99A rear Ride West New tires are fine, but it appears perhaps the forks are bent. More on that later.

Nov 29, 2001 72,558 Rebuilt front forks, investigated whether lower triple clamp may be bent, replaced front axle spacer. Ian Johnston After getting the tires replaced, a Ride West tech told me that my front forks were bent or misaligned somehow, so I'm tracking down that problem. After a ride today, looks like the lower triple clamp is messed up somehow, so I'll replace it with a spare I recently acquired. Replacing the front axle spacer was educational -- the old one was about 15mm compared to the 17mm it's supposed to be.
Dec 13, 2001 72,698 Replaced "original" Fiamm horns with new Fiamm horns. Ian Johnston The old horns were getting tired sounding. Much better now.

2002

Jan 13, 2002 72,860 Replaced left fork leg oilseal and felt. Ian Johnston I discovered a few days before that the left fork seal was leaking oil, and in any case needed to take off the steering head since the legs weren't aligned. Seal replacement went fine, cleaned up a few scratches on the slider; the fork legs were properly aligned, so I left them alone.

Feb 4, 2002 73,037 Adjusted valves, replaced spark plugs Ian Johnston The bike was performing poorly, and felt like the cylinders were out of balance. I was mainly hoping the valve adjustment would do the trick, but they didn't need much adjustment. The spark plugs [picture], however, were coated in baked-on carbon, and replacing them has significantly improved performance.

Mar 1, 2002 73,225 Removed, inspected and cleaned up starter Ian Johnston No problems found, although the starter runs a bit more easily now. Lesson learned: the orientation of the solenoid end-cap is very important.

May 7, 2002 73,743 Checked engine compression Ian Johnston Left cylinder: about 137 PSI. Right cylinder: about 50 PSI. Time for a top-end rebuild.

May 30, 2002 73,750 Top-end rebuild Ian Johnston, Hill Headworks Heads were cleaned and new BMW valves, valve guides and springs installed; valve seats in good condition. Pistons replaced with new BMW pistons, rings, and wrist pins. Cylinders cleaned and inspected -- bores were perfect. All seals replaced (pushrod tube, cylinder o-ring, head gasket, valve cover gasket, cylinder stud o-rings, etc.).

May 31, 2002 73,770 Engine oil and filter change Ian Johnston None

June 12, 2002 73,890 Replaced air filter and spark plugs Ian Johnston None

July 6, 2002 74,142 Sanded valve cover gasket surfaces flat, added silicone gaskets. Ian Johnston None

July 15, 2002 74,355 Changed engine oil and filter Ian Johnston None

July 20, 2002 74,405 Adjusted valves Ian Johnston Right cylinder intake valve required slight adjustment (too loose) and left cylinder exhaust valve was a hair too tight.

2003

March 22, 2003 74,659 Re-adjusted valves Ian Johnston Right cylinder had started clattering -- right exhaust valve adjuster bolt was loose, and had perhaps 1/2 inch (!) of play. Right intake valve was slightly too tight, as were left valves. All adjusted to correct tolerances.

May 11, 2003 74,810 Installed new rear seat hinge Ian Johnston Previous hinge (made of thin stamped sheet metal) had broken in half. New BMW hinge looks to be 3x as strong.

Date	Mileage	Service	Mechanic/Location	Notes
2001
Apr 17, 2001	Unknown (around 70,850)	Pre-purchase inspection	Marty's BMW (Los Angeles)	Needs new: speedo cable boot, intake fittings. Found the rear rim is "slightly" bent, starter needs to be lubed. Right cylinder leaked 100% in a leakdown test (through the exhaust valve), left 12%. Right cylinder 100 psi in compression test, left 120. Stiff throttle cable. I was personally not pleased with the apparent effort that went into the inspection, as they missed a really gummed up carb, and slipping clutch(!).
Apr 27-29, 2001	70,915	Post-purchase repairs	Ian Johnston	Replaced: throttle cable; speedo cable boot; petcocks; spark plug wires; floats; float pivot pins; float valves; fuel line; intake hose-stubs. Cleaned the carbs. Cleaned up and lubed the throttle chain cam and mechanism. Replaced the stock S mirrors with Napoleon bar-ends. Inspected the clutch adjustment (needs to be more thoroughly checked and possibly adjusted). Inspected the air filter, and vacuumed it out.
May 5, 2001	71,010	Clutch adjustment	Cascade BMW	Adjusted the clutch to see if it's really slipping, or just poorly adjusted. It's really slipping.
May 6, 2001	71,030	More post-purchase repair	Ian Johnston	Replaced the clutch cable (although the old one looked fine, so I saved it out) and choke cables. Cleaning out the choke lever housing on the handlebar produced amazing results -- it feels like brand new, clicks into position perfectly.
May 17, 2001	71,106	Clutch and input shaft seal replacement	Cascade BMW	Pretty standard, they also reported that the drive splines are 50% worn.
May 19, 2001	71,180	Tech day repairs	Dave Cavanaugh, Kevin Beretta, Ian Johnston	Re-welded the centerstand with new footpads (it was worn entirely through before), and added a tang. Balanced the carbeuretors.
Jun 1, 2001	71,311	Replaced left float bowl	Ian Johnston	Had to replace the whole float bowl just to replace the little starter jet/choke jet that's pressed into the bowl. Ah well, that one needed to be replaced anyway.
Jun 3, 2001	71,362	Relettered idiot lights, replaced indicator bulbs	Ian Johnston	Took off the instrument pod to replace the tach face light, and ended up replacing all the bulbs and the gasket. Also relettered the idiot light labels with enamel so I can read them again. Image of the renewed face here.
Jun 6, 2001	71,362	Replaced front brake pads, centerstand spacers, instrument lights, instrument light carrier	Ian Johnston	Replaced moderately worn stock front pads with new EBC pads, since I liked them so much on the K75. Replaced the centerstand spacers, since they were as much as 2mm out of true, resulting in the bike resting too far back on the stand. The light carrier and lights were replaced when I determined that the light contacts on the old carrier were well-corroded. Nice side benefit: the lights are noticably brighter now.
Jun 16, 2001	71,471	Adjusted valves and carb floats	Ian Johnston	Re-adjusted the valves to make sure they were set up right. If the PO really did adjust the valves before I got the bike, it's got severely receding valve seats -- both exhaust valves were tight. I suspect that he didn't adjust the valves, though, which means he lied about that service, as well as the changed compression readings. The reason I suspect that is that the valve covers were still glued on with gasket sealant, and he had mentioned having "sealed" the engine as part of preparing it for sale. The adjustment to the carb floats was to try and fix them dribbling gas on my boots as I ride; the fix didn't work though.
Jun 23, 2001	71,515	Replaced left float bowl again	Ian Johnston	Turns out the first new float bowl had a loose overflow tube, so it slowly seeped gasoline, dripped it onto the shifter pad, and thence onto my boot. Very smelly. BMW warranty-replaced it, and the new one is fine.
Jul 15, 2001	71,719	Changed engine oil and filter	Ian Johnston	Uneventful, unless you count two trips back to Ride West to exchange incorrect parts they had sold me. I'm sure they were honest mistakes, but it's frustrating to have a .5 hour oil change take a day and a half.
Aug 5, 2001	71,896	Replaced and rekeyed seat lock	Ian Johnston	The old seat lock rotated freely, making actually locking the seat a dicey affair. When I figured out that this was due to the lock body having been worn down, I decided to replace it, but getting a matched lock costs $50 vs. a generic for $23. So I rekeyed a generic. See the journal for more info.
Sep 9, 2001	72,025	Added Helicoil to final drive "level check" plug hole, changed oil in drive shaft and final drive, replaced turn signal bulb	Ian Johnston and Autosport Seattle	Removed final drive for Helicoil insertion after being unable to remove the "level check" plug. Repaired at Autosport Seattle. Refilled drive shaft and final drive with fresh oil.
Sep 15, 2001	72,090	Rebuilt carbeuretors, adjusted necessary valves	Ian Johnston	Replaced diaphragms and all the little O-rings trying to fix a rough idle. Adjusted the right exhaust valve, as it had tightened up to no clearance. (Watching for possible recession, since the valves were adjusted less than 1000 miles ago -- although I may have done it incorrectly last time, it's possible.)
Sep 29, 2001	72,159	Checked valve adjustment on the right cylinder	Ian Johnston	Exhaust valve was still right where it should be, at .15 mm. Had been worried it had closed up due to seat recession or incorrect adjustment, but all was fine.
Oct 16, 2001	72,312	Replaced final drive oil	Ian Johnston	Oil had indications of water contamination. Looking into why that might have been.
Oct 24, 2001	72,445	Refilled battery electrolyte	Ian Johnston	Not quite down to the plates.
Nov 1, 2001	72,554	Replaced both tires: ME33 front, ME99A rear	Ride West	New tires are fine, but it appears perhaps the forks are bent. More on that later.
Nov 29, 2001	72,558	Rebuilt front forks, investigated whether lower triple clamp may be bent, replaced front axle spacer.	Ian Johnston	After getting the tires replaced, a Ride West tech told me that my front forks were bent or misaligned somehow, so I'm tracking down that problem. After a ride today, looks like the lower triple clamp is messed up somehow, so I'll replace it with a spare I recently acquired. Replacing the front axle spacer was educational -- the old one was about 15mm compared to the 17mm it's supposed to be.
Dec 13, 2001	72,698	Replaced "original" Fiamm horns with new Fiamm horns.	Ian Johnston	The old horns were getting tired sounding. Much better now.
2002
Jan 13, 2002	72,860	Replaced left fork leg oilseal and felt.	Ian Johnston	I discovered a few days before that the left fork seal was leaking oil, and in any case needed to take off the steering head since the legs weren't aligned. Seal replacement went fine, cleaned up a few scratches on the slider; the fork legs were properly aligned, so I left them alone.
Feb 4, 2002	73,037	Adjusted valves, replaced spark plugs	Ian Johnston	The bike was performing poorly, and felt like the cylinders were out of balance. I was mainly hoping the valve adjustment would do the trick, but they didn't need much adjustment. The spark plugs [picture], however, were coated in baked-on carbon, and replacing them has significantly improved performance.
Mar 1, 2002	73,225	Removed, inspected and cleaned up starter	Ian Johnston	No problems found, although the starter runs a bit more easily now. Lesson learned: the orientation of the solenoid end-cap is very important.
May 7, 2002	73,743	Checked engine compression	Ian Johnston	Left cylinder: about 137 PSI. Right cylinder: about 50 PSI. Time for a top-end rebuild.
May 30, 2002	73,750	Top-end rebuild	Ian Johnston, Hill Headworks	Heads were cleaned and new BMW valves, valve guides and springs installed; valve seats in good condition. Pistons replaced with new BMW pistons, rings, and wrist pins. Cylinders cleaned and inspected -- bores were perfect. All seals replaced (pushrod tube, cylinder o-ring, head gasket, valve cover gasket, cylinder stud o-rings, etc.).
May 31, 2002	73,770	Engine oil and filter change	Ian Johnston	None
June 12, 2002	73,890	Replaced air filter and spark plugs	Ian Johnston	None
July 6, 2002	74,142	Sanded valve cover gasket surfaces flat, added silicone gaskets.	Ian Johnston	None
July 15, 2002	74,355	Changed engine oil and filter	Ian Johnston	None
July 20, 2002	74,405	Adjusted valves	Ian Johnston	Right cylinder intake valve required slight adjustment (too loose) and left cylinder exhaust valve was a hair too tight.
2003
March 22, 2003	74,659	Re-adjusted valves	Ian Johnston	Right cylinder had started clattering -- right exhaust valve adjuster bolt was loose, and had perhaps 1/2 inch (!) of play. Right intake valve was slightly too tight, as were left valves. All adjusted to correct tolerances.
May 11, 2003	74,810	Installed new rear seat hinge	Ian Johnston	Previous hinge (made of thin stamped sheet metal) had broken in half. New BMW hinge looks to be 3x as strong.

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Created by Ian Johnston. Questions? Please mail me at reaper at obairlann dot net.