In memory of Jim Adams - an R60/5 build diary

Discussion in 'Airheads' started by backdrifter, Aug 8, 2010.

  1. enzorover

    enzorover Adventurer

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    Forgive my ignorance, but why is it ruined? It's just a gasket, right? Seems to me it's pretty well stuck to the engine side so maybe just slop* a little RTV around it and tighten down the band clamp.

    *by slop, I mean put just enough to insure a good seal and wipe off the excess.
  2. backdrifter

    backdrifter Wannabe rider

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    That's what I was starting to think too, Enzorover. The sleeves/gaskets are still in good shape and I slid the carbs on and they fit very snuggly. I see no reason not to reuse them, am I missing something?
  3. Tin Woodman

    Tin Woodman Mike

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    didn't mean to alarm but the insulators look a little fuzzy and I thought you had already hit them with the dremel wheel. The carbs would probably appreciate crisply defined insulator tubes because the carb throat only constricts marginally when you clamp them. No sense over tightening to make them seal and overstressing the carb body. If you bond them to the stubs at this point, you won't be able to remove the stubs for examination if you ever want to. I may be completely wrong of course but I have seen other rebuilds in this forum go sideways when it came time to tune the carburetors. I'm always worried about leaks when it comes to carburetion.
  4. backdrifter

    backdrifter Wannabe rider

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    Thanks for the follow-up, TW, that certainly makes sense. Luckily I had not ran the Dremel on the sleeves, and they actually look pretty good. I've got some time to play with before I'm actually riding the bike, so I'll play with it as is and order the sleeves if necessary.
  5. backdrifter

    backdrifter Wannabe rider

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    Out to the garage again for some miscellaneous odds and ends.

    I bought some black Rub N' Buff today. I wanted to try it on the clutch and brake lever perches, and also use it to cover this nasty scratch that I managed to put in the swingarm because I didn't cover it while installing the engine :baldy:

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    After the RNB:

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    Sorry the photo is out of focus. The RNB certainly helped, but you can still see it pretty well. Still, any improvement is worthwhile, so I move on.

    Clutch perch before:

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    And after:

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    It cleaned them up a bit and made them shinier, but I'm not satisfied with the overall result, so I'll end up painting them or having them powder coated in the future.

    I wanted to mount the coils, the starter relay, and the voltage regulator and get them all wired up. The starter relay and voltage regulator were no problem. I'm really glad I took the time to label everything properly, it made wiring much easier.

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    Unfortunately, I didn't do the same for the headlight bucket. My painter had called and told me he could squeeze me in if I took my parts in that afternoon, so rather than properly labeling every wire, I just ripped everything out and headed up there. I'm NOT looking forward to the rat's nest in the headlight bucket! :eek1

    Done:

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    And done:

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    Onto the coils, but they're going to need some cleaning up:

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    As it turns out, so will the brackets:

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    I start with the brackets. I clean them up to see what I'm dealing with:

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    They don't seem like they'll shine up easily, so I decide to paint them. I like to go with this paint for jobs like this:

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    Crappy picture, but after the first coat. They're still drying. I'll apply three or four more coats and call it good.

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    While I'm painting, I decide to grab the header hanger brackets and scruff them up and paint them too. I think black would look nice for these, and mine look poor enough that I don't expect them to clean up too well.

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    Too my surprise, though, I'm wrong and they look amazing after some degreaser, hot water and soap, and steel wool, so I decide not to paint them:

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    BMW has a "R" for right and an "L" for left stamped into these. I'm not quite sure why - they look symmetrical to me. Anyone know why? :ear

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    And now it's family time, so no more progress for now. I'm *hoping* to start into the rat's nest in the headlight bucket this week. Wish me luck, I'm truly dreading it.....
  6. backdrifter

    backdrifter Wannabe rider

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    And for no other reason than I'm starting to enjoy photographing the bike, I'll end with a few gratuitous pics that have absolutely nothing to do with the minor progress I made today! :D

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  7. Renner

    Renner combustophile

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    You may actually have fun with this.

    Fortunately for us, German automotive wiring been codified for quite a while as DIN 72552.
    Go here: http://en.wikipedia.org/wiki/List_of_DIN_standards and scroll all the way to the bottom to find it.
    Click on it and it shows the meaning behind the tiny numbers on the electrical components found near the spade terminals.

    Joe 'Cuda' has an article on the ABC site which describes wire color coding conventions. I hope this link works for you.

    http://www.airheads.org/index.php?option=com_content&view=article&id=302:wiring-color-codes&catid=12&Itemid=140

    Things like used wiring looms like to return to where they once belonged. With some luck & attention the harness will offer plenty of clues.

    I read somewhere that painting the headlamp bucket's interior white helps.
    so I tried it... and found it helpful.
  8. Tin Woodman

    Tin Woodman Mike

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    You may want to grind the powder coating off the frame where the coil mounting bracket meets the frame to ensure a good ground. And expose the metal on the mounting bracket itself where the ground wire is attached.
  9. disston

    disston ShadeTreeExpert

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    I think you have to log in which means you have to be a member of the ABC to view the Joe Cuda article. You might find the info else where.
  10. Renner

    Renner combustophile

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    I see, you're right.
  11. disston

    disston ShadeTreeExpert

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    Which is OK really. I'm a member. so everybody else should be also.
    :deal
  12. backdrifter

    backdrifter Wannabe rider

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    More baby steps today. I'm not sure what happened, but my motivation to go out and spend hours in the cold garage has vanished. So I do litle by little. Maybe it's because the temps have dropped some, or maybe it's because the work has changed from large, gratifying, mechanical chores (installing the the engine and new parts into the engine) to small, tedius, electrical ones. I suspect the latter. Regardless, it must be done, so let's go.

    So I start cleaning the ignition coils and brackets.

    Before:

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    And after. Not perfect, but much better:

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    I do at times realize the silliness and futility of going out of my way to sand and paint items such as the ignition coils to make them look better, but they just look so out of place if I don't do it. So I do, or I wouldn't be able to sleep at night.

    Then I find the nicely packaged and labeled fastener kit for the ignition coils. Again, I can't say enough good about BMW Hucky's fastener kit. Talk about a time saver!

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    For the first time in the entire project, this had to come out:

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    I've been very impressed with the masking work my powder coater did. Everything that should be covered is, and anything that shouldn't, isn't. I started to screw in the rear bolt for the right side ignition coil bracket and felt some resistance. Honestly, I can't even be sure that it was powder coat in there. The bike was so dirty, grimy, and in such a state of disrepair that it could have been anything. Found the 6mm tap and cleaned up the threads:

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    Between Rub N' Buff and antisieze, the poor bike has had more silver residue on it than I care to remember. And looks like a dog hair for good measure!

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    Fortunately, it all comes off very easily.

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    I still need to clean off the leads, which I plan to do with a Dremel tool and a light wire brush attachment. Looking back at this post, that's a lot of freaking pics of the ignition coils. Maybe I need to cut back on my photos a bit... Hell, if I had put the camera down months ago, I might have been done by now! :D
  13. kwb210

    kwb210 Been here awhile

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    I just came across your thread, excellent, also enjoy how you've invited all to help you with the project. I am finishing up a resurection of a 1972 R75. her biggest problem was spending to much time just sitting, lots of gummed up stuff and leaky seals etc. Just finished the engine and frame (steering head and swing arm bearings) and now to the headlight bucket. Today I decided i was not in the mood to work on her, then I felt bad that I was not progressing on the project until i read this quote "When stuck or frustrated, clean your work bench." Which I did and found a small bolt I had been searching for. Now I can't wait until after work tomorrow to get back to it! Hope the quote works for many of you as it did for me. :clap
    Regards,
    Kurt
  14. backdrifter

    backdrifter Wannabe rider

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    I know what you mean, Kurt! Really early on in this thread I lost the little ball bearing that retains the key when you insert it in the ignition. I pushed the key in way to hard using my fist, and the entire ignition assembly came apart, sending pieces flying into the open headlight bucket below. I heard the ball bearing go bouncing across the floor and looked for what seemed like hours, but I never found it. Looking back at my photos it would've been somewhere around page 4, which shows it was approximately February, 2011. Oh how time flies.

    Fast forward to the end of 2012, and I decided to clean out and rearrange the garage so I could fit both cars, the Jet Ski, and the BMW project in for winter. I'm cleaning up, I look down at the floor on the other side of the garage and guess what I see? Yep, the ball bearing. Sealed it in a baggie and still have it waiting for installation.

    Yep, sometimes it's just best to sit back and take a break from the project for a bit.

    PS - where can we see some pics of your toaster? :evil
  15. backdrifter

    backdrifter Wannabe rider

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    Time to start facing my fears!

    [​IMG]

    :eek1

    A huge thanks to Renner, who sent me all of this great reference info:

    [​IMG]

    I had planned on wheeling the bike into the house so I could work in good lighting and comfort. That was until I measured the width of the bike and the width of the front door. It would fit, but it was going to be close. That coupled with the fact that there is still ice on my walkway and two large steps that I would have to push the bike up persuaded me to work in the garage instead. Too bad, because I already had the lastest Dakar update on and ready to watch in the background! :clap

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    Instead, this ended up being my workspace for the evening.

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    I had to clean up my tool cart. Being a makeshift home for the engine over the last year had resulted in a lot of dirt, grease, and old bolts accumulating on it.

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    Then I put all the wiring and reference papers on it and got started.

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    New versus old switch cover:

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    Installed:

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    I started trying to reassemble the terminal board and immediately dropped the assembly and lost the contact bushing as it shot across the garage floor. What a perfect start! I grabbed a beer and a flashlgiht and soon found it.

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    Terminal board mounted. I HATE this design. As much as I love the overall design of this bike, I can't believe they use bent mounting tabs to hold this in place. I find it idiotic, and honestly, I'm a bit embarrased by how long it took me to get this assembled again. It would go much quicker if I had to do it again now. I swear that's how this whole project has gone, and I could do another in a fraction of the time that it's taken me to work on this one!

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    Rest of the wiring harness back in the headlight bucket:

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    Starting to wire the harness to the frame.

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    I forgot to take a picture, but the starter relay is all done.

    And this is where I left it for tonight.

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    The wiring doesn't seem like it will be as bad as I've been thinking. It's nowhere near done, but I'm cautiously optimistic now!
  16. backdrifter

    backdrifter Wannabe rider

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    Quick question for the knowledgeable inmates here:

    How similar would the headlight wiring in a '74 R90/6 be to the headlight wiring in my '73 R60/5 LWB?

    I may have access to an R90/6 that I could borrow for a few days to use as a reference for rewiring. Thanks in advance!
  17. chasbmw

    chasbmw Long timer

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    The R90/6 has a completely different and much more complicated wiring system.......... Find a good wiring diagram and follow it, it's not that difficult really:clap
  18. backdrifter

    backdrifter Wannabe rider

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    Hmmmm.... I've started down that path already but was REALLY hoping for the easy way out! :D

    Thanks for the quick response!
  19. backdrifter

    backdrifter Wannabe rider

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    Just a quick bump for some assistance. I just started another thread requesting some help with headlight wiring questions. Any assistance would be greatly appreciated!
  20. mattsz

    mattsz moto-gurdyist

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