Boxerworks.com

That's my COVID 19 project.
edit: just checked the vin...it's actually an 11/81 RS. Sold to me as RT, not that it really matters as the bits are all the same and there's no correct frame to go with it.
It might become a nekkid bike or an RS, but I already have that.

This list is an exercise in knowing what I have and what I need to get.

Feb 2018 I bought a small station wagon full of 1981 R100RS parts.
Frame-proved bent, so gave it to someone that wanted it for something?
Engine. Bean can attached.
The rotor and stator look a bit dirty. No idea if they work.
Transmission, 1981 on, with the clutch actuation bits....

No starter, diode board, swingarm/shaft, no final drive.

I have since bought another frame from an 80/7 and also a subframe
A steering head with lower triple. Needs new bearings. The steering damper rod and knob have arrived. Still need the adjuster bits. and I have the upper adjustment bits in the mail.
I have a SJBMW top triple.

Accumulated over many years...
Wheels, forks, rear shocks, brakes
instruments
Front brake reservoir and master cylinder, hoses, splitter
Guards
Battery holder.
Starter.
Clutch.
Transmission
Indicators
Headlight/housing/lens/circuit board.
Coils, HT leads, caps.
Regulator, bean can.
Both stands
All cables.
Headers & mufflers
Tank & 40mm Bings
Side covers & seat.
A box of 2-3 looms in a state of disrepair...might get one out of that lot?
RS fairings and frames.
Under seat and rear tool holders.
I have a pre 81 final drive. It'll need a cleanup and new splines.
Steering head adjuster nut, bearings. Lower steering damper assembly.

I need
the swingarm with shaft.
diode board.(might have one somewhere?)
Handlebars, brake and clutch lever assemblies.
Switchgear, though I do have some stuff which I'll need to inspect very closely.
Some relays.
Ignition switch and key.
Rear brake master cylinder and reservoir.
Additions:
oil pump.
Clutch bolts/washers x 6
Conrod bolts x 4.
Gaskets: all of them.
Camchain. (prob ok, but I'm in there)

Can anyone see if I'm missing anything from the list?

Shells need replacing.


Journals look good. Light polish only.

The journals look a bit scored but you really can't tell just by looking at them... you need to check them for size, ovality and barreling. You're going to have to do that anyway to get the size and grade of shells you need even if they're perfect.

I would suggest this is something you need to do before you go any further with the project... If the journals are out of spec, you have a major decision on your hands... do you have them ground... many people supposedly in the know say this isn't a good idea with an airhead crank, citing instances of crank failure and the destruction of the hardened journal surface... others say it's OK. Do you replace the crank or do you just look for another engine. I would also suggest, if you decide to go with this engine, you need to check at least the mains and the oil pump housing before making the decision. A bit of extra time spent now may prevent a teardown and an even more difficult decision in the future.

Rob

The leading 4 edges of the inner oil pump rotor aren't perfect. They have some score markings.



I think it's kaput? Waddya think?

This is from Brooks garage, a screen shot from one of his excellent videos.


These were my measurements. It'd be a waste of time reusing this oil pump I expect.


Tomorrow, the main bearing carrier and the crank to come out. I just need to work out how to heat the case to 275F.

SteveD wrote: ↑Mon Aug 17, 2020 5:31 am

The leading 4 edges of the inner oil pump rotor aren't perfect. They have some score markings.



I think it's kaput? Waddya think?

Yup... I wouldn't use them...

Rob

Yep, they'll need replacing. Anyone got a excellent condition oil pump assembly on their shelf just gathering dust?

Their condition made me worry about the crank more than I had been. I pulled it out today and it didn't look too bad. It's already gone for assessment.



I'll wait until I know the results before I commit to any more effort and money in this, except maybe working on cleaning the casing.