Preparing a BMW R80G\S for overlanding.
 

Hi All.

After suffering the misfortune of having my XRV750 stolen, I have recently purchased a 1986 R80G\S. The bike was very cheap and as such it is just intended as a winter hack however I would very much like to overland at some point in the future so I started thinking about what should be done in order to make an old Airhead BMW as reliable and suitable for an extended trip as possible. I have a little bit of experience with BMW motorbikes but any additional advice would be greatly appreciated. I have broken the various areas of the bike down into the following 9 categories and have included some of my thoughts which are totally open to criticisms or suggestions.


Frame

It would appear that the area around the headstock is pretty weak and also susceptible to flexing. Looking through the horizonsunlimited site I noticed that Chris Bright's R100GS actually snapped in half when the headstock weld failed. Something that I really wouldn't want to experience myself! I have seen that HPN reinforce this area with additional struts and also noticed that Kevin Beretta has had his frame strengthened around this area along with the mounting point for the shock. Is this a recommended modification? Is the bike likely to snap in half is I don't do this? It seems like a really big job which I wouldn't fancy doing unless it was totally recommended.

Subframe

Again from reading up on the horizonsunlimited site, it appears that the GS subframe simply isn't up to the job. Is it best to simply unbolt and through the original subframe away and start again from scratch or can the original be modified - if so does anyone know of any contacts in the UK who could do this? Also an idea of price would be greatly appreciated.

Suspension

Front end: My G\S has been modified to a twin disc set up on what looks like the original forks. As such the braking is greatly improved - the thing actually stops now! However the standard forks seem a bit skinny at 35mm so if possible I would like to improve this. My initial thoughts are to purchase the entire front end of an Africa Twin or Super Tenere and work out a way of grafting this set up onto the BMW. In an ideal would the 50mm forks that HPN offer would be great but they are simply too expensive at well over £1000. Any ideas?

Rear end: There is a lot of information on this forum about aftermarket shocks and it appears that fitting an Ohlins, WP or Works Performance shock is a mandatory requirement for overlanding so this will need to be done. After the XRV the BMW seems very low and I was wondering whether it would be possible to jack up the bike by fitting a slightly longer shock to the bike. Does anyone know if this can be done or will I run into problems with the angle of the shaft drive?

Wheels

The rims and spokes on the bike are both badly corroded. Chris Scott recommends fitting heavy duty wheels to any bike that is going to be overlanded so it would seem like the ideal time to rebuild the wheels with HD stainless spokes and excel rims. I would guess that rebuilding the rear wheel could be a bit tricky due to the shaft drive. Has anyone got any contacts in the UK who can do this?

Engine

I guess the name of the game in terms of the engine is to keep it standard - that way ordering spare parts on the road is greatly simplified and the thing should, hopefully, be fairly reliable. The bike has only covered 24,000Km so I would guess that the engine is going to be in pretty good condition. Are there any recommendations for improving the life of wearable parts? Is it worth having the engine rebuilt at this mileage? Should I fit a ceramic clutch plate? Again any advice greatly appreciated.

Gearbox

I've heard that the gearbox on the old airheads is a bit of an achilles heal. Is it worth having the entire box rebuilt before I set off? My bike didn't come fitted with a kickstart but I see that Motorworks (http://www.motorworks.co.uk/) in the UK offer a rebuilt box with kickstart for £420 - seems like a lot of money. Is it worth doing?

Electrics

Quite simply I am very poor when it comes to electrical troubleshooting. Is there anything that I can do to bullet-proof the entire electrical system before I set off? From looking in the motorworks catalogue most electric components seem to be pretty cheap - should I just replace the majority of components with new ones and hope for the best? Ideally I would like to run better lights, a heated waistcoat and heated grips off the bike - will the alternator be OK with these additional drains?

Tank and Fairing

The HPN 43L tank seems to be the way to go so that's what I'll probably end up getting. The G\S doesn't come with any fairing whatsoever and as such will probably be a complete pain to ride long distances on. In terms of adding an aftermarket fairing, does anyone have any suggestions? I've had a look at the Simpson (www.simpson-detour.co.uk) offerings which look pretty good but are they any better alternatives?

Exhaust

Finally in terms of the exhaust system, can anyone recommend a good quality 2into2 low level exhaust system that fits the R80G\S. I like the idea of symmetrical well balanced panniers and a 2into2 low level set up seems to be the best way to go. Any ideas?


Many thanks in advance for any advice or comments that anyone has to offer.

All the best


Alfie.

alfie.
i'm the chris bright you refer to. it wasn't the weld that failed, but maybe 4 or 5cm behind the weld on the horizonal tube it snapped and then the up-tubes and 'strengtheners' went. i have opinions on all your questions, but the memories are too recent of all the 'events' i had on my beemer.

if you're at the hu rally in june i'll discuss it over a pain-killing beer or 3.
good luck,
ChrisB
ps.
try www.airheads.org and www.bmwmoa.org where there is sure to be discussion on all your topics.

Hi, I am currently in Nairobi having taveled 23,000 miles on my 1986 R80 G/S, Leave engine and gearbox standard but overhaul as much as needed, ie new bearings etc, my frame is standard and we are travelling 2 up, not sure what Chris did with his bike but never heard of frames snapping at the front before, however a German company HPN strengthen this bit so it can't hurt any to put extra plates in, rear sub frame definatly needs beefing up, mine was and is still sound now, rear shock, fit the best you can, heard very good things about Technoflex and white power, Ohlins don't seem to be what they once were, Hagons, like mine, just not up to the job. If I was prepping a bike now I would seriously concider fitting a twin shock swing arm and rear sub frame. Fit better fork springs, mine are standard and the bike bounces a lot on rough roads but then the all up wieght of the bike is 500kg, TKC 80 tyres seem good for most things except for sharp gravel but handleing on loose surfaces and mud quite good, good in sand and fine on tarmac, I will be in UK around June unless I decide to ride home, depends how much "fun" I'm having in Africa by then and how the bike is, rear wheel is sporting about 30 cracks around the spoke holes but they dont appear to have changed since Damascus so should be OK? I live in Hampshire so if you want to see the bike when it gets back email me. Cheers, ChrisK

hi alfie
I have just finished rebuilding a r100gs the things I would do get ernie from overland solutions to make a new sub frame,there is some I heard of doing frame simlar to hpn in hamshire or talk to ernie
electrics check out snowbums tips on the electrics on the airheads site.karl prager has some great tips replace the dieode board with one from eurotech in the usa
I'll post web address later
chris and grant's road test makes great reading
cheers nobby

hi alfie
part2
gearbox yes rebuild it £80 for new bearing do it yourself replace detent spring as well

Alfie,
You can find a lot of info on your questions on the HUBB. Check especially the debate between Grant and Chris mentioned above. Here's a nice website on homegrown tranny rebuilds:
http://www.mysunrise.ch/users/joerg.hau/mot/gearbox.htm

Also, does anybody have a recommendation for an R100GS subframe welder in the US or Canada? It would be nice to just send it in for reinforcment, if possible.
Kevin

Thanks for all the advice guys (and cheers for the chat CB). I’m planning on a trip down to Ernie’s in the next couple of weeks in order to get the subframe, crash bars and side stand sorted out. I’m also planning on overhauling the electrics ASAP along with adding an Ohlins or WP shock and an HPN 43L fuel tank. Not sure what I’m going to do about the gearbox – the bike is now showing just over 25,000Km, surely it doesn’t need rebuilding yet?

Thanks once again fro all the advice.

ATB

Alfie.

Re the gearbox, an 86 at 25,000km probably has sat a lot - which means that the bearings are in severe danger of rust, so yes, replace all the bearings. I've seen some very rusty internals. Airhead gearboxes are susceptible to getting water inside through the speedo cable boot, then rusting and exploding when a bearing fails as a result. Bearings are inexpensive - Motobins does the whole set for something like £50-60. Or just send them the box and let them do it all. It's not a diy project unless you have good mechanical skills and tools.

Re electrics, check out Motelektriks Omega system - 400 watts instead of 280, and all upgraded components. Tell Rick I sent you. http://www.motoelekt.com/

ChrisK, re the rear rim - see the story on my bike for details on this problem. You should be ok, but no guarantees. Keep a very close eye on it. Count the bad ones etc. That 500kg is two-up or solo?

------------------
Grant Johnson

Seek, and ye shall find.
------------------------

One world, Two wheels.
www.HorizonsUnlimited.com

Alfie, when you get Ernie to make a sub frame and pannier frames make sure he puts the rack high enough, mine was too low and the rear left hand indicator has melted because of the exhaust gasses, also make sure there are enough places to hook bungies, straps etc, I had some extra ones welded on in Germany as there were insufficient hooking places.

Alfie, Here's what Ernie did for my frame. All the bits and pieces behind the main frame are his. A complete new rear frame etc.

K
http://www.nohorizons.net/