25 March 2003 - After owning the bike for
about one year I have finally started to take it apart. The first part I will
remove is the driveshaft. To remove the driveshaft, you pry the rubber seal
forward on the rear of the shaft. Remove the two 14mm nuts that secure the
shaft to the rear drive. Slide the rear of the shaft forward and remove. Next I
started to remove the four nuts that secure the exhaust to the engine. Of
course, all four nuts were rusted solid to the studs. Upon trying to remove
them the studs twisted right off.
26 March 2003 - Well the
driveshaft was a bit more complicated than I originally thought. The top bolt
that secures the rear driveshaft housing to the rear drive was simple enough.
The lower one had a footboard and brake linkage in the way. The brake pedal is
secured to the linkage by a 17mm nut. I removed it and had little luck freeing
the pedal from its stud. I applied some heat and gave it a good whack. It came
right off. Once both of these were moved the 14mm nut was accessible and
removed from the stud that secures the rear driveshaft cover to the rear drive.
Then I thought could push the driveshaft forward enough to remove it (wrong). I
discovered that there is a clip in the front of the driveshaft that needed to
be pried out to allow the driveshaft to be pushed forward to allow it to be
removed. Below shows the driveshaft with all of the various pieces loose prior
to removal.
It was interesting to find that there is a
small flat cover held on the front of the rear driveshaft cover by four screws.
Under this I found a leather gasket with a spring around the shaft for sealing
it (like a modern seal). The cover was mounted to the rear drive via a cork
gasket.
27 March 2003 - Today I
removed the left side exhaust and the rear passenger footplate. Next I removed
the petcock, aircleaner and carburetor. I loosened the nuts that hold on the
exhaust to intake preheating tubes. Once they were removed the tubes would not
come loose from the intake. I applied some heat to the point where the tubes
enter the intake and gave them a couple of whacks with the hammer. They came
out. Next I removed the small "L" shaped bracket that secures the
intake to one of the shifter housing bolts. Once this was done the intake was
easily removed.
29 March 2003 - Today I removed the
transmission and engine. There are three nuts that secure the transmission to
the engine. The hidden one is at the bottom. In order to remove the engine the
gas tank had to be removed.
25 June 2003 - I
have decided to put all of the details of the frame-related restoration on this
page as well. The photo below shows the drivers seat removed. Prior to
disassembly
29 June 2003 - Finished the front seat.
Sandblasted all parts including the seat rubber, it came out quite nice. The
photos below show the blasted and parts repainted flat black.
15 August 2003 - I have
finally located and have what I consider the hard to find part of my
restoration. The top yoke plate that the handlebars mount too. Searching for,
and finding parts for these machines is an order of magnitude more difficult
than the post 40's BMW's. The yoke plate I found is in good condition. I
purchased it from Wolfgang Bernhard in Germany and it was not cheap! It is the
civilian plate with the casting for the steering lock, but fits the bike
perfectly. The photo shows the yoke plate fitted loosely.
Here is another view
showing the repo civilian headlamp. This is the first time I have seen the
handlebars in their correct position. It is pretty cool. The rear of the plate
that fits over the center point of the plate (steering damper screw hole) does
not slide down flush right now (barely misses) and I did not try and force it.
The forks may have shifted since the bike has been pushed around without this
plate on it for some time.
26 September 2003 -
Tonight I removed the rear seat. It was attached to the rear luggage rack by 2
brackets in the front and two in the back. A soak in penetrating oil overnight
loosened all of the bolts for easy removal. Notice the rubber hand grip cover.
I am not sure I have seen this on any other bikes I have looked at thus far.
Next I removed the
headlamp and top fork plate in order to get the front forks off of the frame.
See the top fork ball bearings, the bottom are the same. I will probably
upgrade to modern roller bearings.
The photo shows the
frame and forks separated. I am going to carry the frame to the car wash and
spray it down good to remove the grease and oil.
27 September 2003 - I
carried the frame to the car wash and sprayed it down with degreaser. After
hosing it down to remove the large grease deposits I examined the frame. I had
thought about the possibility of keeping the current paint job if it was not to
bad under the grease. Well, its too bad so the bike is going to get a total
repaint. See the nice clean frame.
Upon getting the grease
and dirt off I found several spots on the bike where the black over paint
washed off. Underneath was the original gray.
25 October 2003 - Today
I spent the entire day sandblasting the frame, fenders, fork parts and part of
the tank. I left some of the paint on the tank so that the painter can match
the color. What was interesting was that on the frame and fenders I had the
black outer paint then the base of gray. On the fork parts, I think they were
off of a civilian bike. The colors I found from top to bottom were black, some
type of pink, gray, and then black. I have to say that sandblasting these big
parts outside is quite messy, I would recommend a respirator.
November 3 2003 - This
weekend I sandblasted more small parts so that the painter can paint them the
same color as the bike. The stage I am at in the restoration is cleaning lots
of small parts for painting. Its tedious and slow going.
November 5 2003 - Below
shows a photo of the disassembled handlebar parts. They are degreased and ready
for sandblasting.