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Blood Sweat Tears and Grease => Projects => Restorations => Topic started by: advCo on Jul 19, 2018, 02:17:10

Title: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Jul 19, 2018, 02:17:10
Over the winter I picked up this F650 ST. I had been wanting a newer, more reliable bike that I can use as a daily while I wrench on the vintage stuff. The seller disclaimed that it had some milky oil, and after doing some research on these bikes I narrowed down the possibilities to a faulty water pump seal, or a blown head gasket.

Once I got the old girl home, she looked pretty clean. About 50k miles and the motor should be barely broken in. The bike actually included all the original paperwork, and the maintenance records since new.

Besides the obvious coolant leak issue, a few cosmetic issues, leaking fork seals and some pretty thin brake pads will all get addressed.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Jul 19, 2018, 02:22:17
So I cleaned the carbs and fired her up to get the oil circulating so I could drain it and see whatís what. No bueno. Looked like a melted Frosty mixed with soot and poo.

I decided to start with the simpler solution and replace the water pump shaft and seal, despite the fact that the maintenance records said it was done fairly recently. The water pump seal is basically a 20k mile maintenance item on these motors and from everything I can tell is the only crux of the Rotax lump.

Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Jul 19, 2018, 02:26:04
After the water pump is done, I changed the oil and test ran the bike again just to get it warmed up. It looked ok in the OIF tank but draining out came the same frothy mess.

So into the motor we go. Itís a pretty straightforward motor and game apart pretty easily. Once I got the head off, it was pretty clear that the culprit was the head gasket.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Jul 19, 2018, 02:36:16
A pile of parts were ordered including new circlips, rings, a set of kibblewhite valves and seals, base and head gasket, etc.

I ended up replacing the thermostat since the PO had deleted it for some reason that is beyond me.

The whole top end went out to a local machine shop that builds racing motors. Cylinder and piston clearance measured within spec, and the original cross hatch could even still be seen on the barrel.

Machinist surfaced the mating surfaces between the head and cylinder. They pulled vacuum on the head and cylinder,  skimmed about .003Ē off between the two surfaces, cut in the new Kibblewhite valves and shimmed the valves. I need to pop the valve cover off and check the clearances before I run it.

The last few months Iíve been building a new kitchen in our house from scratch and coming up to the home stretch on that project. So I hope to get back on this as soon as thatís finished.

Currently, the motor is back together, just needs the carbs installed and itís ready for a test fire.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: trek97 on Jul 19, 2018, 08:25:43
WOW, sorry for your troubles.  But looks like its going your way now!!!    8)
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Jul 19, 2018, 09:30:10
That oil is nasty, but you'll sort it out I am sure.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: canyoncarver on Jul 19, 2018, 14:39:14
She'll be like new. 
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Jimbonaut on Jul 19, 2018, 14:44:39
Sweet man, we can embark on our ďrestorationsĒ together and see how the plans of mice and men unravel


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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Brodie on Jul 19, 2018, 19:52:01
I love the look of a fresh milled head.
What is your plan for the styling of the bike?
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Hurco550 on Jul 19, 2018, 20:35:33
Yisss! I'm in

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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Jul 19, 2018, 22:19:43
Welcome aboard fellas.

Plan right now is to get it running and ride it. Iím going to get some crash bars from Evil Chop and possibly wrap the plastics in white vinyl. Probably ditch the windscreen for something a bit more aesthetically pleasing, but Iíll see how this one performs on the highway before I go swapping anything out.


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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Aug 17, 2018, 11:28:59
The kitchen is ramping down so Iíve been able to spend a little time on the bike.

There was a big nasty blob of tar smeared along the bottom of the stator cover. I assume it was just weeping some oil and a PO didnít feel like pulling the cover to replace the gasket. The cover itself is a little nicked up, so Iíll use some slightly thicker material to make a gasket and put a thin coat of Yamabond along that bottom edge to avoid any drips. I used acetone and a brass wire brush to get the crap off. What a mess.

Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Aug 17, 2018, 11:32:19
I pulled off the broken clutch actuator and luckily I found the missing spline hanging out in the recess where the actuator sits inside the Clutch cover. Glad I was able to recover the piece as itís a big chunk and couldíve caused some major problems down the road.

I got the new ($85 ) actuator installed and the snap ring that holds it in place was slightly deformed. I ordered a pack of 300 assorted metric external snap rings from amazon for about $12 so Iíll swap it out for a new one before I button the cover back up.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: JustinLonghorn on Aug 17, 2018, 12:34:28
Vroom vroom, soon.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on Aug 17, 2018, 18:05:45
I got the new ($85 ) actuator installed and the snap ring that holds it in place was slightly deformed.

https://www.canampartshouse.com/oemparts/p/can_am/420259203/rack-actuation-clutch

Sooner or later, you'll figure out that this is a DS650 engine and the parts are half as much.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Aug 17, 2018, 19:13:08
https://www.canampartshouse.com/oemparts/p/can_am/420259203/rack-actuation-clutch

Sooner or later, you'll figure out that this is a DS650 engine and the parts are half as much.


Yeah. I figured that out about 3 months ago after I had already ordered this in from BMWAG. Too late.


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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Aug 21, 2018, 09:26:09
Cut out some gaskets for the left and right side covers last night, installed new snap ring, greased and reinstalled the clutch actuator and then finally sealed the engine back up. Of course I forgot to grease the splines so I had to pull the clutch cover off again to grease them up, on the plus side I can tear down that side of the engine pretty quickly now lol.

Got the carbs back on and all the cables hooked up. Unfortunately I made a rookie mistake and overtightened the clutch release arm and cracked the casting, so Iím going to have to order a new one of those.

I double checked the valve clearances before I buttoned up the top and they read as follows:

         L      R
Ex.   .09  .14
In     .07   .11

The spec for valve clearances is 0.10mm-0.15mm for both intake and exhaust, so the left side are both a bit tight. I was thinking I would just ride it for about 300 miles, then take it down to recheck the clearances and shim if necessary and take that time to retorque the head just to see if the clearances change at all. However I know that over time the intakes are likely to loosen and the exhausts are likely to get tighter. So, the more I think about it, I will open the valve cover back up and see whatís in there for shims and swap em around it possible to get the left side back in spec and Iíll just order in whatever shims I need. The machine shop said they changed out the shims after the installed the new valves but Iím not sure what they actually did.

Iím itching to get this thing on the road but Iíve waited this long I donít really want to run it with tight valves.

Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on Aug 21, 2018, 10:01:18
I have a bunch of the plastic bits in decent shape if you ever need them.  I never will.  No side covers, but mainly fairing bits.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Aug 21, 2018, 10:08:07
I have a bunch of the plastic bits in decent shape if you ever need them.  I never will.  No side covers, but mainly fairing bits.

Cool. I actually plan to keep it all in stock plastics (for now) but I'm going to vinyl wrap them in white. I think all the bits on this bike (except the side covers) are in good shape but I'll definitely take the extras if you don't need them. I was actually thinking about using them as a mold to make some one off fiberglass bits based off the original fairings but a bit more  "edgy," we will see.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Hurco550 on Aug 21, 2018, 11:26:08
I am going to use them as a mold to make some one off carbon fiber bits based off the original fairings but a bit more  "edgy"

fixed.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Jimbonaut on Aug 21, 2018, 11:30:08
Me (KLR) and mate (DR) went for a midnite ride around the city last night - dual sports on quiet city night streets is f-u-n.  You're gonna have an absolute riot on this thing mate, hope you're in the saddle soon!
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Aug 24, 2018, 15:59:26
Was able to get the cooling system filled up, oil system bled and primed and filled up with oil. Hooked up the bottle and she fired up after 2-3 cranks. Seems to be running well. A little backfiring at low RPM but I may have the idle speed set too low. Itís also puking petrol through the T inlet to the carbs so Iíll have to pull the carbs again and adjust that to fix that issue, may be contributing to the backfiring as well if itís running too rich. I also had a couple of vacuum lines (emissions stuff I think) disconnected so Iíll straighten that all out later.

https://youtu.be/GzjlCsvvcVE

Going out of town for the weekend so Iíll get back on it next week. Fix carbs, reinstall the fuel tank and seat and we should be on the road.

Getting closer!



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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: JustinLonghorn on Aug 28, 2018, 18:33:26
My man!
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: trek97 on Sep 02, 2018, 10:38:05
Thats great dude.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Sep 14, 2018, 09:19:18
I tried to take it for a test ride yesterday, but its running like garbage and backfiring like crazy. Found some vacuum leaks around the carb boots so I guess I have to pull them off again and check the intake boot. Will also check the exhaust headers for leaks, the nuts on the studs for the exhaust only call for 10 nm torque which is barely even tight so I may snug those up some more now that its been heat cycled a few times.

ALSO. I pulled the clutch in and something popped in there and I completely lost the lever. I hope nothing broke  >:(
Going to have to pull the LH cover off and investigate. Probably going to have to drain the coolant again to get in there.  ::)
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Sep 14, 2018, 09:37:22
Poo, hope it's nothing serious.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: trek97 on Sep 14, 2018, 14:27:38
Dang dude.  All that stinks.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Jimbonaut on Sep 14, 2018, 14:56:51
These things are sent to test us.  If in doubt, get the hammer out.  And hit things.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Sep 14, 2018, 15:49:39
SO this is a big single with 2 carbs and 2-1 intake? Can you swap it out to a single carb intake?  That would have to be easier to tune etc? Or maybe not. but one thing I know about German shit, it's usually over complicated when it doesn't need to be.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Jimbonaut on Sep 14, 2018, 16:09:26
but one thing I know about German shit, it's usually over complicated when it doesn't need to be.

Aint that the truth.  I took apart a BMW mid 80's K100 throttle assembly at work the other day, and there was some kind of chain and gear assembly in there connected to the throttle cable.  Great when it works, bit of a nightmare when it went south.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Hurco550 on Sep 14, 2018, 16:16:59
its funny you say that, and I wonder where the "turn" came in design, because my 76 r90/6 BMW is really one of the most well thought out machines to work on that I've ever owned. Now my buddy drives a late model (2010 I think) bmw something or other car, and talk about an overcomplicated piece of kit.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Sep 14, 2018, 16:20:44
Thank god most times it doesn't break but man when it does it's fucking crazy complex to fix.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Sep 14, 2018, 16:25:51
Yeah Mike, its a big single with 2-into-1 cylinder intake and 2 Mikuni BST33's. I know others have fit different carbs (irk's TMs) but not sure whats out there on single carbs.

Regarding the simplicity - the motor is made by Rotax in Austria and the entire bike is built/assembled by Aprilia in Italy. That should say a lot  ;D
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on Sep 14, 2018, 16:35:11
SO this is a big single with 2 carbs and 2-1 intake? Can you swap it out to a single carb intake?  That would have to be easier to tune etc? Or maybe not. but one thing I know about German shit, it's usually over complicated when it doesn't need to be.
I have a 2-into-1 intake for these.  Just need a carb to fit the wishbone in the frame.   The intake is off of a DS650 Bombardier.  This Rotax motor is incredibly reliable, very well engineered, and not complex at all.

If you popped the clutch when you pulled the lever, make sure you have the adjustment right.  That's what it does when the lever is in the wrong starting position. 
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Sep 14, 2018, 16:47:53
I have a 2-into-1 intake for these.  Just need a carb to fit the wishbone in the frame.   The intake is off of a DS650 Bombardier.  This Rotax motor is incredibly reliable, very well engineered, and not complex at all.

If you popped the clutch when you pulled the lever, make sure you have the adjustment right.  That's what it does when the lever is in the wrong starting position.

You mean the lever/arm on the LH side cover (where the cable end attaches to?). It may need to be turned another notch.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on Sep 14, 2018, 16:53:14
As you know, since you had to replace it, the clutch actuator is a worm gear.  The actuator shaft (the part that the cable turns) needs to be in the engaged position when the arm and cable is put on so that when you pull the lever it actuates.  Before you put the arm and cable on, you can spin the worm gear completely in both directions all the way to the end of the gear, so it's easy to get confused where it needs to be to hook up the cable.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Sep 14, 2018, 17:04:13
As you know, since you had to replace it, the clutch actuator is a worm gear.  The actuator shaft (the part that the cable turns) needs to be in the engaged position when the arm and cable is put on so that when you pull the lever it actuates.  Before you put the arm and cable on, you can spin the worm gear completely in both directions all the way to the end of the gear, so it's easy to get confused where it needs to be to hook up the cable.

Yes, I realized that the first two times I put that back together. The clutch seemed to engage/disengage as normal before I attempted it while the bike was running. Now there seems to be some slop between the actuator and the actuator shaft (which doesn't seem right at all). I'll post a video later. I really don't want to drain the coolant and pull the entire cover off again.

Is there a specific position that the shaft needs to be at when the cover is installed? Or is it all just relative to the arm and cable once its all back together?
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on Sep 14, 2018, 17:08:50
Don't give up on this thing.  They're super reliable once all sorted.  You just bought into an abused bike.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Oct 04, 2018, 09:36:04
So the last time I ran it, there was some major vacuum leak issues going on. I hate pulling the carbs on this thing so I've been putting it off.

Last night I pulled the carb rack and removed the intake manifold to check it for cracks. Some minor cracking inside the boots but nothing that went all the way through and the rubber is still soft and pliable. I smeared a thin coat of Yamabond between the manifold and the head and reinstalled it. Normally I would just do 1 thing at a time but if I never pull these carbs again I'll be happy. So I blew out the jets and passages again, and double checked the diaphragms for cracks. Everything there checked out, so I put a thin coat of Yamabond on the mouths of the intake boots where the carbs seat. Re installed carbs, I'll let the Yamabond set up and test fire after work today to see if its still leaking.

If it is I guess I'll source a new intake manifold.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: JustinLonghorn on Oct 04, 2018, 11:47:37
Fingers crossed, my man.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Oct 05, 2018, 13:13:08
Well, no luck on that "fix"

Its running super lean at idle. Won't go beneath 2k RPM and still backfiring through the airbox so its gotta still be leaking vacuum somewhere either in the carbs or the intake manifold.

There were some cracks inside the intake boot where the lip of the carb seats, but nothing on the outside. No used intake manifolds available and new is $127.

Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: canyoncarver on Oct 05, 2018, 16:39:04
Liquid electrical tape.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Oct 05, 2018, 17:38:44
Liquid electrical tape.

Hmm. Probably worth a shot. I wonder if that stuff can tolerate the heat? Stuff I looked up on Amazon had a heat tolerance up to 175*F.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: trek97 on Oct 05, 2018, 17:39:54
 Maybe.
Plasti-dip is good for 200 degrees on their website
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: trek97 on Oct 05, 2018, 17:51:20
Plasti-dip also makes Re-rack.  A fix for dishwasher racks...but donít give a heat tolerance.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Oct 06, 2018, 11:25:22
Get the self fuzing tape its silisone, hi heat and fuel safe. Wrap that around all thw rubber it will sealmit all and stay pliable.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Brodie on Oct 06, 2018, 21:49:44
This stuff.
http://www.vintageconnections.com/Products/Detail/133 (http://www.vintageconnections.com/Products/Detail/133)
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Oct 08, 2018, 13:03:56
Ordered some of the self-fusing tape from Matt. Will wrap the intake boot up as well as I can and see how it fares. If it improves or fixes the issue I'll go ahead and order a new intake boot.

Will report back.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on Oct 08, 2018, 13:46:30
Intake boots get too hot for self fusing tape.  It'll last a few days, tops.
 *unless it's Pyrosil
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on Oct 08, 2018, 14:05:20
Also, don't forget, these carbs are unfortunately prone to have issues if the air box isn't in perfect condition.  You can be lean because of the air box side, not just leaky intakes.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on Oct 08, 2018, 15:47:52
Just to be sure:  Did you thread the crank lock in when you pulled the top end to rebuild it?
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on Oct 08, 2018, 15:53:52
Also, make sure you've been here: http://faq.f650.com/FAQs/BackfiringFAQ.htm#Airbox%20to%20Exhaust%20Header%20Line
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Oct 08, 2018, 15:54:57
Just to be sure:  Did you thread the crank lock in when you pulled the top end to rebuild it?

Yessir. Checked and double checked cam alignment, turned motor over a few times and checked it again.

Also, make sure you've been here: http://faq.f650.com/FAQs/BackfiringFAQ.htm#Airbox%20to%20Exhaust%20Header%20Line

Been through there a few times. I am convinced I need to deal with the intake boot before moving on, as spraying starter fluid around the intake boot caused surging. That and the high idle condition lead me to believe it is an issue on the intake side rather than exhaust gaskets etc, most of which I have checked.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Oct 22, 2018, 10:42:23
Nothing super exciting to report. I pulled the carbs completely apart for the 100th time and went through them with a super fine tooth comb. Threw the bodies in the ultrasonic cleaner, along with the brass. Replaced all 4 o-rings in each carb. I noticed that the PO had placed the plastic spacers on the needles above the circlip, rather than below (toward the slide body). So I reassembled those correctly. Set float heights to 14.6mm and set the mixture screws to the stock setting 3.5 turns out.

Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Hurco550 on Oct 22, 2018, 13:27:00
I hope that's all it needed man. TIME TO RIDE!
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Oct 24, 2018, 09:43:38
https://youtu.be/ZjLq0EIvXCs

Sheís running great after the thorough go-round with the carbs. Iím sure it was a combination of the incorrectly assembled needle spacers and crusty old o-rings.

Next up is to address the chatter in the clutch. I pulled the left side cover off again and removed the clutch assembly for inspection. I checked all the fiber discs and pressure plates on a flat surface, and everything looked great. They were pretty sticky as there was hardly any oil between a lot of the plates. Itís been a few years since this bike has moved under its own power so thatís not surprising.

I wiped everything down, generously oiled up all the discs and reassembled. Clutch springs all measured right where they should be. I need to grab the correct moly grease for the clutch activator rack & pinion, then Iíll slap everything back together and test it again.

I drained the oil before pulling the side cover, there was a tiny bit of residual crap in the bottom of the OIF tank from the leaky head gasket, but no more nasty chocolate milk oil!


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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: JustinLonghorn on Oct 24, 2018, 09:58:43
My man!
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Oct 24, 2018, 10:06:05
Nice work!
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Hurco550 on Oct 24, 2018, 10:28:34
 Awesome dude!

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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on Oct 24, 2018, 11:00:45
This is why mine has dual TM34 carbs.  Fuck these sensitive jawns.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: canyoncarver on Oct 24, 2018, 12:36:02
Nice work man.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Oct 29, 2018, 10:08:17
Friday we closed the office early. I ran home, threw the tank and seat back on the bike, put the bike in the back of the truck and brought it down to the inspection place. Ran over to the tax office to get my title transfer and registration done. The bikes finally road legal. Put about 150 miles on it this weekend without any issues.

Bike is super comfortable. I love the riding position. Seems like it might be running a little rich as I only managed about 100 miles before I hit the reserve on my first tank. Definitely needs an overhaul on the brakes and fork seals so Iím going to order the parts this week.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Hurco550 on Oct 29, 2018, 10:35:09
About time! So glad you didn't give up on this man. That'll be a noble steed for you!
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on Oct 29, 2018, 10:37:45
So rad.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: JustinLonghorn on Oct 29, 2018, 11:16:36
My man! Nice work, now ride the wheels off of it.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Oct 29, 2018, 11:17:50
Yep. Nice
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Oct 30, 2018, 09:45:25
Rode in to work yesterday, and then over to my buddy's place to go and pick up a Porsche 914. On the way home last night, I noticed the headlight was getting dimmer and brighter randomly. Not proportionate to RPMs at all. Happened with both high and low beam. I've already verified that the VR is in good shape and charging well. Not sure what could be causing it to randomly change brightness.

I definitely want to replace the headlight with something brighter, its OK but there's no streetlights on a lot of the country roads around here so its pretty damn dark at night.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on Oct 30, 2018, 09:49:45
Most likely a loose or corroded ground to the headlight.  I would first check the 3 pin connector that's attached to the back of the light itself, maybe even replace it.  My old truck used to do this, as well.  I replaced the connectors and good as new.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Oct 30, 2018, 09:53:42
+1 to what Irk said. Get an Led from Matt and maybe his aux lights they light up half the county lol.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Oct 30, 2018, 10:01:53
Sounds about right. I'll check into it. I definitely want to add some aux lights once I put some crash bars on there.  Thanks for the input. I'm used to headlights dimming out at idle on the Honda twins due to crappy charging systems, so this confused me a bit.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Mar 29, 2019, 09:35:59
So I've been having a puddle under the bike since I took my last ride before the new year, I thought I had a slight oil leak and had been seeing a few drips here and there. When I got back I noticed a lot more fluid under there and upon further investigation, found it was coolant. Been so busy with the Bus and other projects that I haven't felt like messing with it until yesterday.

 I dried everything off and checked all the hoses, they were dry. Felt around under the thermostat and got some moisture from the seal behind the thermostat. Drained the cooling system, pulled the thermostat and tightened up the bolts behind it, they were pretty loose. Wondering if they loosened up from heat cycling?

Anyways I refilled the cooling system and purged all the air, reinstalled the tank and she fired right up. Put a bit of cardboard underneath and I'll check today after work to see if there's any more drips.

There's fork oil all over the front brake rotor, I've known the seal has been gone for a while but I finally bit the bullet and ordered fork seals, front and back pads. Debating whether to do chain and sprockets now or wait until after the season, sprockets still have a good bit of meat on them.

Also, something thats been bugging me for a while is the sticking odometer. The trip works fine but the odometer will stick and only work intermittently. I think I'm going to have to pull the speedo and clean and grease it and make sure nothing is stripped out or broken.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: JustinLonghorn on Mar 29, 2019, 09:54:11
Soon you will be back in the wind.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 11, 2019, 11:31:20
So this happened. Torn down for fork seals (check out the front brake pads), brakes and fluid flush, and chain and sprockets.

Rear tire is at about 60% I could replace it but I think Iíll get the rest of the mileage out of it.

I think I figured out that my oil leak is coming from the return hose from the OIF tank, those crappy worm gear clamps finally wore through the rubber, so I think I will replace the entire hose and better clamps.

Going to replace the coolant lines and clamps while Iím at it.

To do list:
-replace fork seals/dust covers. Fill with oil
-clean calipers and replace pads
-bleed brakes
-replace chain and sprockets
-replace oil lines
-replace coolant lines, re fill with coolant.
-re torque head
-clear out tank filler drain line
-install new grips
-remove clock and replace with VM and USB port
-clean and grease speedo/odometer
-replace bulbs with LEDs, possibly headlight
-mount panniers
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Jimbonaut on Apr 11, 2019, 12:40:32
Man I like this bike.  In eschewing the beak, the front end has an Africa Twin vibe which is a great thing in my book.  Once you tick off that to-do list mate you'll be tearing strips off the Texas highways and byways in style.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on Apr 11, 2019, 19:39:37
So this is what they look like stock.  LOL.  Jealous of the impending ride.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: clem on Apr 12, 2019, 14:40:28
You're really not playing around with this thing. Very clean bike for the price.

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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 17, 2019, 14:14:21
Front and rear pads done. Rear sprocket replaced but need to get some new Nyloc nuts for it. Once I get the wheel back on I can bleed the brakes and final torques on all that good stuff.

Waiting on new crush washers and fork oil to button up the forks but the seals are done.

Made an acrylic plate Iím going to use inside the top case to bolt it down to the rear rack. Might need some longer bolts and fender washers. Going to wait to mount it until itís on the ground and we can both sit on the bike. I donít want to mount it too far forward that it sucks tor a passenger.

The odometer has been sticking since I got the bike and there were some notes in the service history about it. The tripometer works fine so I ruled out the cable, lower housing and gearbox inside the speedometer. Disassembled the speedo and found a couple of buggered up gears on the odometer ticker.   The actual plastic gear on the ticker had a couple teeth missing to the point where itís not catching and that must be causing it to miscount. Iím hoping to get a replacement before the ride.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Apr 17, 2019, 15:38:46
Might as well reset to 000000. Start fresh. ;D
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: clem on Apr 18, 2019, 20:45:28
Could you print one?

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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 22, 2019, 09:33:16
Productive weekend, got the brakes bled front and back, chain and sprockets done and everything torqued up. Discovered my chain slider is non existent and the 2 chain rollers are worn over halfway so Iím going to try  and get them in.

Bike is back on 2 wheels. Ran into some whack ass wiring while I had it apart that I want to fix.

Discovered why there was a huge gob of RTV on the right case cover. Cracked. Sucks as thereís none available on eBay right now so it looks like itíll just have to get patched up for now until I can track a good one down.

The third photo is one of the wiring components I canít exactly figure out. Itís definitely some sort of relay but canít be stock the way itís installed.

Red wire has a 30amp inline fuse and runs straight from the battery. One brown wire goes to the horn, one brown wire is cut and taped off. One or two wires go to headlight harness. I was thinking it may be an old alarm system relay that has been disabled?
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: pidjones on Apr 22, 2019, 09:50:33
Might be able to weld the cover and grind down. I've seen remarkable repairs on aluminum, even the crappy case cover castings.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 22, 2019, 10:37:50
Might be able to weld the cover and grind down. I've seen remarkable repairs on aluminum, even the crappy case cover castings.

Good point. I think it will be an epoxy repair for the time being. I doubt I'll be able to get it welded up between now and next Friday, but I'm going to call around.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 22, 2019, 20:12:44
Top box mounted. May add some brass spacers to fill up the gap in the rack but weíll see how it performs in the shakedown.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: trek97 on Apr 22, 2019, 20:16:23
Nice!   8)
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: canyoncarver on Apr 23, 2019, 00:16:23
Nice, that's huge and water proof.   How thick of plastic is the container bottom?
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 23, 2019, 01:25:22
Nice, that's huge and water proof.   How thick of plastic is the container bottom?


About 1/16Ē. I wish it were a bit thicker but Iím confident it wonít go anywhere.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: clem on Apr 23, 2019, 09:21:27
https://shop.advanceautoparts.com/p/blue-magic-products-quiksteel-reinforced-epoxy-putty-2-oz-16002tri/11406385-p?c3ch=PLA&c3nid=11406385-P&adtype=pla&gclsrc=aw.ds&&gclid=CjwKCAjw7_rlBRBaEiwAc23rhnwTh7OZqd06pyMIXpZKlBEctxQ5RelBIFyE0eQsRQO5Osed8Fc4rRoCY5YQAvD_BwE
I used this on my outboard motor to repair some corrosion. The guys at Rocky Mountain ATV are big on this stuff while ADV riding for on the trail repairs.

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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Apr 23, 2019, 09:30:04
Rad
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 23, 2019, 09:37:48
https://shop.advanceautoparts.com/p/blue-magic-products-quiksteel-reinforced-epoxy-putty-2-oz-16002tri/11406385-p?c3ch=PLA&c3nid=11406385-P&adtype=pla&gclsrc=aw.ds&&gclid=CjwKCAjw7_rlBRBaEiwAc23rhnwTh7OZqd06pyMIXpZKlBEctxQ5RelBIFyE0eQsRQO5Osed8Fc4rRoCY5YQAvD_BwE
I used this on my outboard motor to repair some corrosion. The guys at Rocky Mountain ATV are big on this stuff while ADV riding for on the trail repairs.

Nice, I was going to use good old JB Weld but maybe I will give this stuff a shot.

I'm going to change the oil after I re-torque the head so I will pull the side cover, clean the crap out of it and epoxy it up.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Apr 23, 2019, 09:39:48
If you can't get that easy, JB makes one almost the same I have used with success. It's a puddy stick not the goopy liquid and you can really shape it and sand it etc. once cured.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 23, 2019, 18:43:50
Got me thinking...
(https://i.ebayimg.com/images/g/ZXgAAOSwnipWaLkV/s-l300.jpg)
(https://www.vinylwrap.org/wp-content/uploads/2017/10/21690040_508706339489104_4978279107981737984_n.jpg)

I was originally going to go Satin White, but now I don't know.

(https://i.ebayimg.com/images/g/MjEAAOSwLN5WhyMI/s-l640.jpg)
(https://www.revoltvinyl.com/wp-content/uploads/2018/01/S10-Satin-White3.jpg)
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 23, 2019, 23:07:55
New grips and re-torqued the head gasket tonight. Used some zip ties to keep the cam sprockets aligned.

Got a stripped bolt on the starter, I need to pull it out and see if I can cut some new SAE threads in it for now until I can helicoil it.

Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on Apr 24, 2019, 07:55:26
Helicoils use STI taps.  If you're not using a kit, make sure you get the STI tap for that screw size. 
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Apr 24, 2019, 08:54:18
OURY are nice grips. I liked the set I had on the CX
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 24, 2019, 10:10:54
Helicoils use STI taps.  If you're not using a kit, make sure you get the STI tap for that screw size.

Thanks. Iíve never used them before, I think Iím going to grab a kit so I can have them around

OURY are nice grips. I liked the set I had on the CX

I like them, I have them on the Van Van and had a set on the XL. For whatever reason, every time I order these grips they send me the ATV ones which are 1" shorter and don't fit on motorcycles. I think of the 4 times I've ordered them, I've gotten the wrong ones first 3 times lol.
Title: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 24, 2019, 10:34:17
Got a second wind last night and pulled out this superfluous, hacked up wiring.

The kickstand kill switch was already disabled but just sitting up under the seat. Iím going to solder the wires together and delete it properly, as itís a common failure point.

I removed the relay from up by the headlight. The way it was wired leads me to believe it was an aftermarket alarm system as it was hooked up to the horn with a direct hot to the battery. Deleted it and hooked the horn back up properly.

The ground cable is probably extra but it connected the frame ground where the RR grounds directly to the negative battery terminal, which canít be a bad thing. Iíll make a new one since it worked the way it was.
Title: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 25, 2019, 02:20:15
More boring stuff today I pulled the carbs and gave them a quick once over. Glad I did as the hose that drains the water out of the gas cap was clogged and I think some water got into the carbs. Cleaned some crud out and put a new fuel line on. I'm going to clean the filter in the tank and there is an inline filter so I think I'm gonna forego the external fuel filter for now.

I cleaned out the airbox and airbox to carb boots as there was some funky shit growing in there. Not sure if it was dirt or mold or a combo of both, but I scrubbed the inside and got the carbs reinstalled before I had to call it a night.

I've been working on a 3D printed housing for the voltmeter to fit in the OEM clock space on the dash. Its damn near perfect after 6 iterations but of course I've run out of filament for the 3D printer so I had to order some more for the final version.

T-Minus 9 days til Ozarks. Still quite a bit to do but its mostly small stuff.  Shooting for a test ride Saturday, Sunday at the very latest to work out any bugs.

Vinyl will be here tomorrow for the color change. I need to fill in some screw holes from PO and make sure everything is smooth.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: JustinLonghorn on Apr 25, 2019, 07:53:11
Moving right along...

(https://media.giphy.com/media/93uYptVAHE7C0/giphy.gif)
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: pidjones on Apr 25, 2019, 09:22:19
I'd never give up an external filter that I can see and quickly change on a carbed bike.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on Apr 25, 2019, 09:56:29
+1

Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 25, 2019, 10:16:28
Ok, you guys win. I'll reinstall the fuel filter and add an extra one to my kit just in case.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on Apr 25, 2019, 11:18:04
Fortunately you have a plastic tank.  In all honesty, you could probably go with just the tank filter.  Personally, I like the clear filters as much for a sight as a filter.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 25, 2019, 11:22:11
Fortunately you have a plastic tank.  In all honesty, you could probably go with just the tank filter.  Personally, I like the clear filters as much for a sight as a filter.

Yeah. I'm planning to clean the screen in the tank. And then there is the screen in the fuel line T at the carbs, so really there should be no need for the external filter. That being said a little extra filtration isn't a bad thing.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: canyoncarver on Apr 25, 2019, 11:36:10
Until one restricts flow and you bog down on the freeway.   I don't like multiple inline fuel filters.   If one isn't doing the job, change it.  I had a brand new 5/16 line filter on my zrx.  It wouldn't flow well enough for highway speeds and would bog down.  I know, not even close to the same motor as yours but I've had some annoying fuel filter moments.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 25, 2019, 11:56:50
Here's the housing/bezel/whatever I designed to fit the VM/USB charger into the clock spot on the dash. The void on the base is where I will add an M5 machine screw and epoxy it in place. The recess is there to keep the epoxy in, and holes will give it something to grip to. It gets an O-ring just below the bezel, in the recessed channel.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Apr 25, 2019, 12:30:50
Nice
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: clem on Apr 25, 2019, 13:15:44
Should be gas-n-go when you're done. It's going to get a thorough test!

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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 26, 2019, 09:22:41
Filled some annoying holes in the plastics where the PO installed a dinky little mud flap and some mesh over the openings.

Last night I also replaced the breather hose to get rid of the joint and 2 hose clamps underneath the tank. Sure it worked just fine but I hated seeing the big bulky mess under the tank.

Pulled the air filter to replace the media but I had a lot less filter material than I thought, so I had to Prime some and it should be here Saturday in time for the test ride.

Put some JB on the leaking crankcase cover. I couldn't see the crack from teh inside but I did clean it off really well and grind some of the cracked metal out to get better penetration and adhesion. We shall see.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 27, 2019, 00:34:54
Got the new clutch actuator installed, and while I was there I pulled off the crusty old clutch cable boot. I dug through my box of old cables and found a boot from an old front brake cable. Didnít figure I could fit it over the ferrule so I sliced it down the center and glued it back together with yamabond. Seems pretty strong and itís flexible so it should last a while anyways. Itís better than what was there!

Itís hard to see, but the old actuator was over tightened and cracked around the threads. Iíll hang on to that one just in case.


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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 27, 2019, 00:38:34
I pulled off the luggage racks to modify them for the ammo can panniers...and then decided against it. The whole setup is too heavy, and I donít trust the POs crappy mounting brackets, nor do I have the time to make new ones from scratch.

I ran out of filament for the printer so I ordered a KG roll of black and sent the final print for the voltmeter bezel. Only took 6 iterations to get it right LOL.

Seeing how much I can fit in this case. The answer is: a lot. I want to figure out a way to get some mesh over the lid on the inside. Thereís lots of potential storage up there. Any ideas?




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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: canyoncarver on Apr 27, 2019, 02:32:28
I suggest putting the lightweight stuff in that tail pack.  Put the heaviest items lower in the side bags.  It'll make a difference in wind and handling.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 27, 2019, 12:29:13
I suggest putting the lightweight stuff in that tail pack.  Put the heaviest items lower in the side bags.  It'll make a difference in wind and handling.

I decided against running the panniers for this trip. The steel ammo cans and steel racks are just too heavy for my liking and I don't trust the welds on the PO's racks as far as I could throw them.

With all my camping gear and the box it currently weighs 23.6 lbs. which is pretty much at the recommended weight limit of 11kg for the rack.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: canyoncarver on Apr 27, 2019, 13:09:52
The weight of some of the metal side boxes (panniers) I've seen bother me too.  I run something like these when Patty and I take road trips.  Soft throw over saddle bags are awesome and a great alternative to hard bags.   Way faster and easier to put on and take off the bike.  Cheaper too and one set will fit all your bikes.

http://www.joerocket.com/rapidtransit/te0t1fc61py6pk3erdgswqj940flaz
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Apr 28, 2019, 14:35:34
I run those type too. Cheap, light and stuff well. I put anything I want to stay dry in ziplock bags.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 29, 2019, 13:34:50
Voltmeter/USB charger installed. The way I have it wired it reads about 1v low. Iíll probably change the wiring later but for now Iíll just know it reads low.

I printed it with support material so the overhanging faces didn't sag. Basically just prints a lattice for support that you chip away once the print is done. I G/Flexed in a 5mm machine screw to fasten it to the dash.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 29, 2019, 13:52:21
What else happened over the weekend. I helicoiled the stripped starter hold down bolt. Cut oiled and installed a new filter with some UNI foam. Replaced the chain rollers and slider. The rollers were literally non existent. I donít know if they were taken off and never replaced or what, but all that was left was the one little chunk of slider and the bushings that the rollers slide on.


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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 29, 2019, 13:59:44
Fixed some crappy wiring on the alternator harness, replaced with a vintage connections part that I had left over from another project. New fuel lines and filter.

Put everything mostly back together and took her out for a 20 mile shakedown. I went to the back of the neighborhood and tested the brakes. They locked up no problem when I gave them everything so Iíd say they are good to go. No issues on the shakedown at all, but it feels like a whole new bike.


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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Jimbonaut on Apr 29, 2019, 14:02:12
Right on man, gotta feel good being back in that saddle
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Apr 29, 2019, 14:05:33
Nice work!
Title: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 30, 2019, 12:21:12
Thanks guys. So good news and bad news. Bad news first: I found another cracked boss on the stator cover, so that thing is junk and will definitely need replaced. Good thing is I caught it before I filled the bike up with oil so I was able to prep and put a JB weld bandaid on it. No leaks so far! Parts aren't exactly plentiful for these bikes so I'll keep my ebay notifications on and grab a cover eventually.

Windscreen is busted so I'm going to have to epoxy it back together and I'll use some 5oz fiberglass mesh to reinforce the mounting holes.

I started wrapping the front fender and my technique needs a little work. I didn't want to rush it before the trip so I'm going to put a hold on that part of the project for right now.

The only thing I'm left worrying about with the bike is the exhaust gaskets. The bike backfires a bit on hard decel, and its very common for the mid pipe gaskets to blow out on these bikes. Now I should have just replaced them when I had the whole damn thing apart but of course I was trying to get off cheap. What I don't want is to lose an exhaust gasket when I'm 400 miles from home. I called up a few local dealers and then finally Max BMW and they were the only ones who had the parts in stock. So they're gonna get them out today and hopefully they will show up Thursday. If I have the time I will install them if not I'll just throw them in the bag of parts and that way I'll have them if I need them.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Apr 30, 2019, 13:05:22
Bummer on the cracked case, remember there are many other bikes that use the Rotax in these so widen your search to include those models and you'll get the cover faster. Ask Irk, he has the list.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 30, 2019, 13:29:45
Bummer on the cracked case, remember there are many other bikes that use the Rotax in these so widen your search to include those models and you'll get the cover faster. Ask Irk, he has the list.

Yep, Can Am DS650. I forgot to search for that. Thanks for the reminder. This bike is a weird deal because half the parts are the same as the Can Am, and the other half are Aprilia Pegaso LOL

Here's one for cheap. I wish I thought of this last week. But my repair should hold up fine. I need to get better pics of this one price is right but the pics look like I'm drunk looking at the computer screen. https://www.ebay.com/itm/2004-Can-Am-Bombardier-DS-650-Magneto-engine-Cover-Guard-Stater-Generator/333167292323?hash=item4d92516fa3:g:l84AAOSwn9VaXkmn
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Apr 30, 2019, 13:46:37
Also search Bombardier DS650 as they were labeled that here and some other places before they Brought Can Am name back
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Apr 30, 2019, 13:48:03
is it this side you need? https://www.ebay.com/itm/00-06-Bombardier-DS650-Clutch-Cover-Right-Side-Engine-Case-Waterpump-OEM-B2764/153299397408?fits=Model%3ADS650&hash=item23b15b2b20:g:gpkAAOSwI9FcD9vu
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: clem on Apr 30, 2019, 14:01:53
I'm going to bring that tube of epoxy metal with me.....just in case

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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 30, 2019, 14:04:11
is it this side you need? https://www.ebay.com/itm/00-06-Bombardier-DS650-Clutch-Cover-Right-Side-Engine-Case-Waterpump-OEM-B2764/153299397408?fits=Model%3ADS650&hash=item23b15b2b20:g:gpkAAOSwI9FcD9vu

Nope thats the other side, see above I posted a good deal on one but I asked for better pics.

I'm going to bring that tube of epoxy metal with me.....just in case

LOL I think my repair should hold up but it can't hurt to have a backup ;D
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on Apr 30, 2019, 14:07:51
I didn't go back and look. Hop about this one?

https://www.ebay.com/itm/00-07-Can-Am-Stator-Side-Engine-Cover-711210411-DS-650-7404-7449-Baja/352473167183?hash=item521109b54f:g:GukAAOSwk-9br~c7

^^ never mind yours has shipping in, this one is $10 more after shipping
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on Apr 30, 2019, 14:12:46
I didn't go back and look. Hop about this one?

https://www.ebay.com/itm/00-07-Can-Am-Stator-Side-Engine-Cover-711210411-DS-650-7404-7449-Baja/352473167183?hash=item521109b54f:g:GukAAOSwk-9br~c7

^^ never mind yours has shipping in, this one is $10 more after shipping

I saw that one too, they both have crappy pics LOL if I can get some better pics I will probably buy one after the trip. I'll just leave what I have on there until the next oil change though, when you pull either side cover on this bike you have to pull the tank and prime the oil system
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on May 01, 2019, 09:32:12
Put another 50 miles on the bike last night. I blasted up and back the highway 25 miles then hit some back roads for a bit. Bike performed well. I got new boots last week and Iím still getting used to them so upshifting has been interesting. I may try rotating the pedal up one tooth to give me more room underneath.

Lots of buffering without the windscreen so after I got home and ate I set to fixing that up.

I sanded back all the old adhesive and crap, then G/Flexed everything back together with a layer fiberglass cloth on either side. I did the same on the side that wasnít broken just to add some reinforcement.


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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on May 01, 2019, 09:36:47
Nice work. You can paint that out after to hide it and it will look factory.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on May 01, 2019, 09:38:37
Oh and the boots, do they have a lip on the soles? I have that and it is how I need to shift most bike as my ankle won't go under the shifter, once you get used to it you can shift pretty smooth with the edge of the sole instead of the toe of the boot when the boots are really stiff and your ankle doesn't move much.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on May 01, 2019, 09:41:17
MX boots don't bend.  You move the shifter up to get the boot under it.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on May 01, 2019, 09:45:15
MX boots don't bend.  You move the shifter up to get the boot under it.


yeah but if they have the lip you can use it to shift too if the shifter won't move enough to work, some bikes even one tooth change and the shifting gets shitty in one direction or the other. Just an option I discovered after becoming a gimp.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on May 01, 2019, 09:46:02
Here are the boots. They flex a bit so I do have some movement in the ankle. The toe is just a lot taller than what I'm used to. When I put the shift lever back on I may have put it in the wrong position.

(https://images.rockymountainatvmc.com/images/prod/275/f/for_15_boo_adv-blk.jpg)
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on May 01, 2019, 09:47:48
Ok on those you need to move the shifter. The ones Levi and I have, the sole has an edge about 1/4" wide and it catches the shifter really nice. I could shift the GS1200 BMW that way easily without moving the shifter position.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Jimbonaut on May 01, 2019, 09:57:56
I have similar boots and I found moving the shifter position made getting the boot under there way easier.  Bit of a pain in the ass when I'm rocking the Converse for a quick trip to Canadian Tire but dems da breaks.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Hurco550 on May 01, 2019, 10:01:16
Ok on those you need to move the shifter. The ones Levi and I have, the sole has an edge about 1/4" wide and it catches the shifter really nice. I could shift the GS1200 BMW that way easily without moving the shifter position.
I wear those boots or high top steel toe boots 99.9% of the time I ride. They are similar enough in "height" that I never really have to adjust things.

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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: SONIC. on May 01, 2019, 10:39:06
Yep move the shifter.
makes quick jaunts in tennis shoes annoying though.
(I see that as a good thing as now I just put the boots on to avoid the annoyance of having to lift my whole leg to shift without them).
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on May 01, 2019, 10:52:16
I think I need to move the shifter.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: canyoncarver on May 01, 2019, 11:45:55
I put an slightly longer than stock aftermarket shift lever on my KLR.  Took a try or two to get it right for my boots. 
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: SONIC. on May 01, 2019, 11:51:06
MOVE THE SHIFTER
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: SONIC. on May 01, 2019, 11:51:47
In case you missed it before  ;D
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Jimbonaut on May 01, 2019, 11:55:02
Leave the shifter.  Grow duck feet instead.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on May 01, 2019, 11:55:46
Actually I'm going to throw the boots away, wear flip flops and shift with my big toe.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on May 01, 2019, 11:56:37
I put an slightly longer than stock aftermarket shift lever on my KLR.  Took a try or two to get it right for my boots.

This is really what I need. The shifter is at least an inch shorter than I'd like.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: trek97 on May 01, 2019, 12:32:05
Actually I'm going to throw the boots away, wear flip flops and shift with my big toe.

Just cut the toes out of your boots, flip flop style.

(http://www.dotheton.com/gallery/11494-010519103634.png)
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: SONIC. on May 01, 2019, 12:37:11
Careful with the flip flops, been there done that!
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on May 01, 2019, 12:38:52
Isn't this a thread about a motorcycle?

P.S. - Gross
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: SONIC. on May 01, 2019, 12:40:35
Isn't this a thread about a motorcycle?

P.S. - Gross

Not that I can tell  ;D
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on May 01, 2019, 16:06:06
Sir Longhorn hooked me up with these soft bags. Should be a perfect addition to the rig for this trip. Thanks dude!

The bags came with rain covers, which I assume arenít for riding but more for parking overnight to keep things dry?
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: canyoncarver on May 01, 2019, 16:17:37
Sir Longhorn hooked me up with these soft bags. Should be a perfect addition to the rig for this trip. Thanks dude!

The bags came with rain covers, which I assume arenít for riding but more for parking overnight to keep things dry?

When it rains on the ride, pull over and put the rain covers on when you put your rain gear on.  It'll keep the whole bag dry.  They are not just for parking.  If you ride without them in the rain, the water will find all kinds of ways into your bags, especially at speed.  I also put certain things in ziplock bags as well.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on May 01, 2019, 16:23:06
When it rains on the ride, pull over and put the rain covers on when you put your rain gear on.  It'll keep the whole bag dry.  They are not just for parking.  If you ride without them in the rain, the water will find all kinds of ways into your bags, especially at speed.  I also put certain things in ziplock bags as well.

Cool, that makes much more sense. I will probably grab a dry bag to put my clothes in, that way I don't have to worry too much about it.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: canyoncarver on May 01, 2019, 16:25:29
Cool, that makes much more sense. I will probably grab a dry bag to put my clothes in, that way I don't have to worry too much about it.

Yeah, I use contractor grade trash bags on the insides sometimes and carry at least two extras.  Way cheaper than dry bags and multi-use.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on May 01, 2019, 16:25:42
Get you some dry bags, like for kayaking.  You can get sets of 3 or 4 in various sizes for like $15 at most sporting stores.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on May 01, 2019, 16:26:47
I use the thick garbage bags and then good ziplocks for small stuff I want to stay dry. rain covers just add hassle.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: JustinLonghorn on May 01, 2019, 18:31:02
I always carried my clothes in a dry sack stuffed in those bags. I would also do like Kelly said and put the rain covers on while I was getting my Frog Toggs on.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: clem on May 01, 2019, 20:28:23
Sir Longhorn hooked me up with these soft bags. Should be a perfect addition to the rig for this trip. Thanks dude!

The bags came with rain covers, which I assume arenít for riding but more for parking overnight to keep things dry?
That's the core of DDT right there. I figured old Justin was a good dude minus his accent. Let's just hope it doesn't rain during the daytime.

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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Luugo86 on May 01, 2019, 21:21:34
Careful with the flip flops, been there done that!

 That's what im talkin about
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: canyoncarver on May 02, 2019, 13:46:08
I always carried my clothes in a dry sack stuffed in those bags. I would also do like Kelly said and put the rain covers on while I was getting my Frog Toggs on.

Two thumbs up for Frog Toggs.  It's what I use for my rain gear too.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on May 02, 2019, 14:08:50
Frogg Toggs got me through the microburst storm at Mid-O all dry two years ago.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Hurco550 on May 02, 2019, 14:21:43
Frogg Toggs got me through the microburst storm at Mid-O all dry two years ago.
Giving yourself the Dutch oven in a trash bag poncho is way better though.

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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: pidjones on May 02, 2019, 20:36:02
We carry the Frogg Toggs on the GW and they have been good for both rain and (over the mesh armor) cold. Including a deluge from Chattanooga to Birmingham about five years ago.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on May 03, 2019, 09:18:41
I have the frog toggs too but last ride to NH it rained so much I wore them the whole ride 8+ hours and they got ripped. Need a new set for this season but they are cheap and light so worth it.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on May 03, 2019, 09:28:42
Every Wal-Mart in America has them.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on May 03, 2019, 09:37:11
Every Wal-Mart in America has them.
Ha yes, however I got my set for $4.00 at Marden's in Maine LOL.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on May 03, 2019, 21:36:33
So the prologue to the trip. Yesterday I got out of work early and did some shopping to pick up some last minute supplies. Came home and installed the modified/painted racks for the soft bags. Got those buttoned up, top box back on and then put a few misc parts on that have been hanging up since the head gasket, like the skid plate. I plasti dipped the silver plastic bits.

The other day I ordered the mid pipe exhaust gaskets Iíve been avoiding and they came in yesterday. At about 8:00 after I was mostly packed I decided fuck it, Iíd install them. Well little did I know it would be a god damn fiasco. The old gaskets were shot, yes, but the mid pipe had been over tightened and it was all deformed so when I put the new gaskets in it leaked like a mofo. I let it cool, torques it all down again and no luck. At about midnight I decided to take it all apart again, use some high temp RTV On the joint and go to sleep. The leak was bad enough last night I wouldnít run the bike this long for fear of burning up a valve. So by the time I went to bed after showering and finishing packing it was 2 am. The last thing I thought was ďI hope this thing doesnít leak in the AMĒ




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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: trek97 on May 03, 2019, 23:17:35
How'd it get along w the rtv or shims or both?
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on May 04, 2019, 09:56:38
At 5 AM yesterday I woke up with my fingers crossed. Fired the bike up only to find it was still leaking pretty bad. I let it get hot and stuck a box fan in Front of it to cool everything back down. Tightened everything up when cool and it seemed to quiet the leaks down. Definitely still not a perfect seal at the mid pipe gasket but nothing like it was. I set off and fueled up, listening for any signs of it getting worse and it didnít, so on I rode.

We made it 500 miles to camp, the last 2-3 hours were in the rain but my gear and rain covers kept everything pretty dry.

I had to stop at a Loweís parking lot to rotate the shifter back. On the upshift stroke it hits the case when itís rotated and it goes into every gear except second, which is dangerous and annoying as hell. So I just got used to shifting with the side of the boot.



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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Jimbonaut on May 04, 2019, 11:02:06
I don't see any beer in that last photo.  I'm concerned.  Is everything ok?
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: irk miller on May 04, 2019, 12:29:00
I don't see any beer in that last photo.  I'm concerned.  Is everything ok?
Clearly, huffing too many exhaust fumes from leaky mid-pipes has impaired judgment.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on May 05, 2019, 11:24:56
Yesterday was a good day. We got a late start after a wet night and morning, but the rain cleared out for some mid day twisties. Before the riding, we headed into Hot Springs and grabbed breakfast. Cool little city with tons of character.

Bike ran well heading up into the mountains. No issues other than a skid plate mounting tab breaking off the frame and the chain stretched to the point of slapping. Once we got to camp I zip tied the skid plate and tightened and lubed the chain. It was a cold ass night but we just grabbed breakfast and ready to head south.






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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on May 06, 2019, 00:52:30
Today gave us perfect weather, cool and sunny in the high 60/low 70s most of the day. We hit breakfast at the Ozark Cafe, and then rode on to Mount Judea which was about 60 miles of assorted tight switchbacks, long sweepers and damn near perfect pavement. Headed south from there up to Mount Magazine, and then south down 7, which from Ola AR south is absolutely fantastic. The 650 was right at home in 4th gear on the sweepers around 60mph. I may put on a 17T front sprocket to give me a little lower revs on the highway and a more versatile 4th gear. We blasted down the highway from there and wound up in El Dorado where we are staying the night.

So after the blast on the highway (which was wide open with very few cars), I topped the bike out at 90 - which ainít right but Iíll look into that later. After getting off the highway I noticed a lot of chatter in the chain and it seemed really loose. We made it to the hotel and I checked it out and sure enough it was loosey goosey. So I set the tension properly and we headed to a local place for some grub. Kept hearing the noise on the way over and when we got to the restaurant I checked it again. WAY too tight. Anyways long story short I somehow roasted this chain. itís a brand new DID 520 O ring chain (I say brand new, as in I just opened it - I guess whose to say it didnít sit on a shelf for 20 years before I got it).

Anyways, hereís some pics from today.


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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on May 06, 2019, 08:55:49
Nice, that looks like a spot I need to get too someday. I think if I start planning now I might make 2 years from now's GTG LOL.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on May 06, 2019, 10:13:54
Nice, that looks like a spot I need to get too someday. I think if I start planning now I might make 2 years from now's GTG LOL.


Yep Iíll be coming again.

So I went to get a new chain from a cycle shop local this morning but he didnít have any 520. Annoyingly I had considered throwing the old chain I took off in my top case just in the off chance something happened. But I didnít.

Next closest is a Honda dealer in Ruston which is about 100 miles south. Going to lube the piss out of it and cross my fingers that they have a chain.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on May 06, 2019, 10:52:12
Weird the chain has stretched that much in so short of time? Sitting on a shelf wouldn't make it change, sitting in a pond would LOL. Good luck but check the alignment, sounds like you may have the wheel offset from the front sprocket causing a side load on the chain maybe.
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on May 06, 2019, 11:34:18
Weird the chain has stretched that much in so short of time? Sitting on a shelf wouldn't make it change, sitting in a pond would LOL. Good luck but check the alignment, sounds like you may have the wheel offset from the front sprocket causing a side load on the chain maybe.

Yep I checked everything. Alignment was good and sprockets were straight using a straightedge to check for runout. The chain is just toast. Itís a new O-Ring chain, the only thing I can think of is when I adjusted and lubed it on Saturday night, the chain lube broke down the o rings somehow and caused the rollers to wear. Iíll post the video later but thereís audible chatter and side to side play.


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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: Maritime on May 06, 2019, 11:36:07
Shitty, hope you find a replacement!
Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on May 07, 2019, 10:54:26
Yesterday morning I limped the bike along to Ruston and luckily was able to get a new chain. I paid for the o-ring chain and the kid at the parts counter cut me a standard chain the first time. So after about 1.5 hours of waiting to get the right chain (I have no idea what took so long to get it cut to length), I had a new chain in hand. Replaced it in the parking lot and adjusted the tension.

It turns out I was adjusting the chain tension wrong all along. Itís a little misleading because the manual and sticker on the swingarm say to check chain tension under no load. I took that to mean ďback tire in the airĒ as the manual states to check it on the center stand, or on the side stand. Well the rear wheel is in the air on the center stand so I went with that. Turns out thatís useless, and what it really means is to check the tension with the bike under its own weight, but without a rider. So I had the chain too tight which resulted in my crappy MPG and absolutely roasting the DID chain I put on a few weeks ago. Transmission still works fine so my dumb mistake didnít cause any lasting damage.

We blasted through Arkansas to Alexandria, LA where I peeled off the group and hauled ass back to Texas. Made good time and got back at about 5:00 after finally hitting the road at 11:30 or 12:00.

Total miles logged over the weekend was 1,440.

Other than the chain and a loose clamp on a coolant line yesterday morning, the bike ran like a champ and is thoroughly broken in now.

Next up are some changes I know I want to make after the weekend, including some bar risers and new bars, and a 45T rear sprocket to just slightly drop the RPMs. Oh and I definitely need some new rubber. Also going to start specing out a wheel set for the dirt.




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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: advCo on May 07, 2019, 10:55:00
A couple of my favorite runs from the weekend:



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Title: Re: 1997 BMW F650 ST Bluebird - Repair, maintain, ride.
Post by: clem on May 07, 2019, 18:03:19
The bike held up great. That is a really nice feeling when you tear something apart then put 1400 reliable miles on it. Oh and I'm pretty certain that the white lines are dirt roads 😎

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