BMW R80ST technical questions on re-assembly

Discussion in 'Airheads' started by bpeckm, Jan 29, 2013.

  1. Renner

    Renner combustophile

    Joined:
    Jul 11, 2007
    Oddometer:
    2,789
    Location:
    sunny SoCal
    I'm with you. #1 guess. :D

    RE: taken after chasing a short in the main bundle. I'd re-wrapped with SR tape
    (aka self-fusing silicon tape, I recommend it, we use it at the shop on turbine engine harnesses).
    Hence the wrap.

    Fresh pics. now with GS forks.

    [​IMG]

    [​IMG]
    #21
  2. bpeckm

    bpeckm Grin!

    Joined:
    Apr 2, 2008
    Oddometer:
    7,038
    Location:
    Road Island
    Thanks...it makes sense, given the length of the bundle after putting in the various connectors in the frame jig....

    :D

    Got the headlight holder-thingy painted tonight, I am going to put in the "big" headlight from the '70s airheads... :evil

    :D
    #22
  3. Renner

    Renner combustophile

    Joined:
    Jul 11, 2007
    Oddometer:
    2,789
    Location:
    sunny SoCal
    :lurk
    #23
  4. bpeckm

    bpeckm Grin!

    Joined:
    Apr 2, 2008
    Oddometer:
    7,038
    Location:
    Road Island
    OK, since we are batting 1.000.... next question:

    Does a "normal airhead" tool tray fit in the regular tool box location? I always used mine on my /6, and I don't have one on this bike and figure I can easily find a "regular" tool tray, and modify it to hang it in place, and ain't nevah going to find one of these:'

    [​IMG]

    It looks to be short.... or perhaps a MONOLEVER tray?



    :ear
    #24
  5. Renner

    Renner combustophile

    Joined:
    Jul 11, 2007
    Oddometer:
    2,789
    Location:
    sunny SoCal
    ST & G/S specific, innit.

    have you asked these guys? http://www.re-psycle.com/

    couldn't hurt.

    personally I'd fab a one-off out of a milk carton, glue it in place with expanding foam and carve off the flash with the GF's electric knife... good to go. :nod
    #25
  6. norton73

    norton73 drinkin'

    Joined:
    Dec 20, 2003
    Oddometer:
    8,634
    Location:
    Beautiful Downtown Springville, Alabama
    I've got some pics from when I was tearing down my wife's R80ST showing how some of the wires were routed;

    [​IMG]

    There's some relay locations and other stuff there too.

    More pics here; R80ST
    #26
  7. bpeckm

    bpeckm Grin!

    Joined:
    Apr 2, 2008
    Oddometer:
    7,038
    Location:
    Road Island
    Thanks, Norton73.... I think I remember an old post/thread about the accident that I see in your pics? There are some good ones in there showing the routing of some wires around the headstock that I should be able to use... I appreciate it!

    [​IMG]

    [​IMG]

    :evil
    #27
  8. bpeckm

    bpeckm Grin!

    Joined:
    Apr 2, 2008
    Oddometer:
    7,038
    Location:
    Road Island
    I'm getting the wires all run and put back together, putting the grips and perches on a non-22mm bar (grrrrr....) and in putting the ignition switch back... I have an extra, un-identified wire


    It is in the bundle that goes to the back of the ignition switch. It would logically go on the one spade terminal that is left over, in the center (which is normally the hot/red so that one could "tap into" the hot circuit there).... but this wire is Green with a Purple tracer

    It's got me stumped... can't find it on any wiring diagram, and I lost the filmstrip of the dis-assembly in my photographic memory :lol3

    Guess I''m going to have to do some tracing and continuity-work, unless someone has a bright idea....???


    :D
    #28
  9. Renner

    Renner combustophile

    Joined:
    Jul 11, 2007
    Oddometer:
    2,789
    Location:
    sunny SoCal
    Joe "Cuda's" Tech-Tips article on Wiring Color Codes at the ABC site indicates green w/ violet may be the "trigger for headlight relay".

    beyond that, I've got nothing
    #29
  10. bpeckm

    bpeckm Grin!

    Joined:
    Apr 2, 2008
    Oddometer:
    7,038
    Location:
    Road Island
    That would make sense... I think. I will try to scope it out. The color combo is a new one to me!

    :D
    #30
  11. bpeckm

    bpeckm Grin!

    Joined:
    Apr 2, 2008
    Oddometer:
    7,038
    Location:
    Road Island
    Renner.... you nailed it, muh man! Once I got home I looked for "the other end" and sure enough it goes into #86 on the headlight relay.... AND, upon closer inspection (ahem!) of my ever-so-faint Haynes wiring diagram, I have come to the conclusion that it is indeed the green/VIOLET tracer (not purple!).

    Those wiring diagrams have fooled me more than once with the tracer colors: hard to tell between green/blue, green/black, green/violet.

    Every day that you learn something new makes you older, if not wiser!!

    :wink:
    #31
  12. Renner

    Renner combustophile

    Joined:
    Jul 11, 2007
    Oddometer:
    2,789
    Location:
    sunny SoCal
    glad that worked out well :thumb

    FWIW, I like having my ignition switch wired to run with the headlamp on/off option... maybe that's an old-school thing.

    (could be a control issue too) :D
    #32
  13. bpeckm

    bpeckm Grin!

    Joined:
    Apr 2, 2008
    Oddometer:
    7,038
    Location:
    Road Island
    Yeah, I did that on my son's XS650... put an on/off switch right on the bucket.


    :evil FWIW it can be done really easily with the three position BMW switch: just move the "ignition" (green/black) wire to the post for "parking lights" (grey), and you can then run/start with the switch in the first "parking lights" position, and turn the headlight ON by going to the last position.... :freaky
    #33
  14. Renner

    Renner combustophile

    Joined:
    Jul 11, 2007
    Oddometer:
    2,789
    Location:
    sunny SoCal
    you've got it; that's the way :nod

    I sorta figured we're on the same page :freaky
    #34