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

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

  1. backdrifter

    backdrifter Wannabe rider

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    Thanks mattsz! It probably would've helped to post a link to it, huh? Sorry, it was late and I wasn't thinking straight.

    I'm moving on to wiring the frame up, but any help on the issues in the thread here would be greatly appreciated!

    http://www.advrider.com/forums/showthread.php?t=854951
  2. backdrifter

    backdrifter Wannabe rider

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    Well, it's time to update this. I've been pretty productive this weekend, but I haven't updated as frequently as I normally do. I know myself, if I let myself get too far behind, I'll get lazy and abandon the build thread rather than face the work of catching up, so I'd better just stay on top of it!

    I knew I would be spending hours on wiring this weekend, so I decided to go ahead and bring the old girl into the comfort of the house. Her temporary (just ask my wife!) home:

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    What I had accomplished before this weekend:

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    My set up and one of my dogs wondering what the hell I was up to!

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    Baby steps, but some progress:

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    A brown/black mystery wire that is still causing me concern:

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    I got as far as I could, and then started a separate thread here asking for help:

    http://www.advrider.com/forums/showthread.php?t=854951

    A huge thanks to bmweuro and Big Bamboo for their assistance. I really don't know what I would do without this site! :clap After posting the help thread and while waiting for replies, I moved on to wiring the frame and associated work. I had to clean up the horn before I could mount and wire it. Honestly, I expected to need to buy a new horn down the road, but it cleaned up really nicely.

    Before (sorry for the blur, I was trying to focus on the pitting):

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    Getting there:

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    Beautiful!

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    Then I needed to paint the horn bracket. I decided to paint a few other pieces while at it.

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    Down to the "paint booth":

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    Sprayed:

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    I also cleaned up and painted these fender braces and the steering dampener plate (sorry, no after shots yet):

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    I didn't see a need to replace the wiring harnesses. All of my wiring is in great shape, just dirty. So I spent some time scrubbing each harness before installing it.

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    Main harness in place loosely, spark plug wires in place:

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    Taillight wires pulled through the subrame. I was worried about this - I really thought it was going to be hard to push these wires back through the subframe, but it went very smoothly.

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    Starter wired:

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    Polished up horn and newly painted bracket mounted:

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    Speedo cable installed:

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    Hard to see here, but wires are tidied up some with zip ties:

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    And that's where I stand for now. Still working out a few concerns on the headlight wiring, but getting closer. I'm not really happy with the headlight wiring right now, but my main concern is just to get everything connected. Next time I need a project - maybe next winter - I'll go back in and try to make it as tidy as some of the amazing examples I've seen on this site (bpeckm's comes to mind immediately, as does elite-less' latest proejct). I don't see any reason I shouldn't be able to try firing her up within the next week or so. I need to buy a battery, and I need new muffler clamps, but other than that, things are looking pretty good! :clap
  3. sky44

    sky44 Adventurer

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    wow that looks awesome. getting very close, can't wait to see it done!
  4. mattsz

    mattsz moto-gurdyist

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    I love that you've already got your mirror installed! I'm sure I would have done the same thing! Too bad the cylinder base gasket sealer is orange... they should make it rub'n'buff colored...

    Looks fantastic, keep 'er coming!!!
  5. RobboJ

    RobboJ Adventurer

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    Great thread, watching it get nearer to completion is excellent
  6. gertiektn

    gertiektn KetchikanBeemer

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    Just a note.. the coils might be better pointed aft,,, wet weather may affect performance. The coil bodies have to have perfect contact with the frame and holders.. meaning where they are clamped paint should be avoided. The clamps have to ground the bodies. On my bikes they are installed with the flats forward.

    Have enjoyed the thread from the start.. I am about the same place in my rebuild on a R75/7.

    Jim
  7. georgesgiralt

    georgesgiralt Been here awhile

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    Hello Jim,
    I have to disagree with you ! The coils are wire grounded and do not need to be grounded at the body.
    As they are oil filled you should ensure that no corrosion takes place hence the painting. Otherwise the body could pit and leak the oil (which is a nasty stuff by the way). You have just to ensure the contact with the clamps is good to conduct heat as much as it can.
    Of course preventing the rubber boot and the plugs to get rain mist is a good thing.
  8. kwb210

    kwb210 Been here awhile

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    The coils need to be reversed. I can't really say they are facing the right or the wrong direction, hey, they don't have a face... :rofl
    The connectors should be facing to the rear. Probably the most logical reason is rain water running down the high tension wire and into the coil.
    Looks good!
    Regards,
    Kurt
  9. Max Headroom

    Max Headroom lost in the '70s

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    I've been riding airheads for only 28 years, so I'm still learning stuff. This "coil facing the rear" thing is a new one on me though.

    Personally, I can only think of two scenarios where the forward facing connections *could* be an issue. One would be if the rider decided to ride in the rain without a fuel tank, and the other would be if the rider decided to partially submerge the bike in a stream or lake,although there could be other consequences too . . . .

    The coils are well protected from the elements under the fuel tank, and their relative position matters very little providing the H/T leads are fitted with the appropriate rubber boots IMHO. Having ridden through many torrential storms over the years without the least concern for the coils getting wet, I really can't see a problem.
  10. backdrifter

    backdrifter Wannabe rider

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    Thanks for all the comments and suggestions. I mounted the coils forward, as shown, because that's how they were when I removed them. I've seen a lot of other photos of them facing forward. Mounting them backwards makes some sense, but as I have everything currently run, I'm not sure if I have enough length on a few wires (spark plug wires included) to reverse them. For the time being, I'm going to leave them as-is.

    I do plan to grind some paint away from the brackets, and a bit of the powdercoating on the frame right under the brackets (you'll never see it) for better grounding. I'll add a bit of dielectric grease to keep the elements out and prevent oxidation.

    Thanks agian!
  11. georgesgiralt

    georgesgiralt Been here awhile

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    Hello !
    No need to scrap this new paint. It will serve no purpose at all.
    If you look at new coils of the same type, they are painted from top to toe. And if you look at the modern design they are even in a plastic housing ! (the crack-o-matic grey coil is one example).
    So let your new paint in peace !
  12. backdrifter

    backdrifter Wannabe rider

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    Thanks for the info, I appreciate it!

    Well, I've got about 20 things that I can think of left on the "to do" list before I can consider starting her. It's too damn cold out to the ride now anyway, so I'm not in a huge hurry, but I have decided to do at least one thing on the bike each day.

    Unfortunately, I woke up at 4AM this morning to my baby girl throwing up. Some kind of bad stomach virus. Two hours later it hit my wife, and they're both out of commission. They had been sleeping for the last few hours, which gave me some time to work on the bike while I sit here like a ticking time bomb just waiting for the virus to get me. :lol3

    Can you tell what I tackled tonight?

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    Sorry, I was lazy, so no "during" photos this time. I'm really happy with how these turned out.

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    And a few without the flash, but with a shaky hand. :cry

    Still gotta get that damn masking tape off of the valve cover:

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    I'm really happy with the length of these. Just a bit shorter than the stockers, I think they look really nice.

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    And that's it - only 19 more things on my list now! :clap
  13. gertiektn

    gertiektn KetchikanBeemer

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    The coils I bought are 6 volt aluminium clad and the body contact was critical due to the notches in the holders designed to bite the body.. so I figured wrong..and I stand corrected..

    I do however live in rainy southeast Alaska rainforest.
    Last year's reported rainfall of 144" for 12 months as dryer than average,,:clap
    Nice project result.
  14. Tin Woodman

    Tin Woodman Mike

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    For some reason, the designers were insistent on grounding the coil casing to the frame. It seems that's what the spur on the mounting bracket is for.
  15. Tin Woodman

    Tin Woodman Mike

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    Giving it more thought, the spurs might just be a mechanical grip. Subtle but apparently intentional. Hope you didn't get the flu. . .
  16. chasbmw

    chasbmw Long timer

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    But the coil mounting bolts are often used as a grounding point on airheads, your /5 may be different
  17. backdrifter

    backdrifter Wannabe rider

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    Thanks! I got something, but only for a day or so. Not nearly as bad as my wife and daughter got it.

    Speaking of, the two of them will be gone all weekend, so I should get lots done one the bike in the next few days. Look for some updates soon!
  18. backdrifter

    backdrifter Wannabe rider

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    I worked on the bike all last night again. I didn't get as far as I expected, but I'm happy with where it sits. First I went shopping. I had to buy some of the fluids I'll need before starting her. I also needed hose clamps, an in-line fuse for initial start-up, and rubber bushings/gaskets for mounting the fenders. Once I got those, I came back home and:

    - Cleaned up the handlebar wiring
    - Installed the tachometer cable
    - Set the points gap to .015"
    - Mounted the fork and driveshaft hose clamps
    - Mounted the carbs
    - Ran the throttle cables
    - Ran the clutch cable (still need to look at that - I have excessive slack, even when backed out all the way at the clutch lever)
    - Mounted the tank and fenders

    My writing is getting lazy, so here's some pictures.

    Carbs:

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    Setting the points gap:

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    Installed my new battery that arrived two days ago. I went with a "replacement" for a Panasonic battery. It has a 2 year warranty and was $45, so I figured I had nothing to lose by giving it a shot. Also, a dumb reason to pick a battery I know, but it is black, which fits very well with the subdued tones of the bike.

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    Hose clamps on, throttle cables run, tank on:

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    Starting to make sense of the front wheel mounting hardware (using my daughter's pretty pink princess blanket to protect the fender):

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    Original BMW pinstriper's mark on the left, my painter's mark on the right next to it, and duct tape to hold the bolts in place while I mounted the brackets:

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    Front fender mounted:

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    On to the rear:

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    Then adding the seat for the full effect:

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    By then it was 12:30AM and I was tired, so I crashed. Here are some better photos in the morning light:

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    Let's go see what I can get done today!
  19. Tin Woodman

    Tin Woodman Mike

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    You get more done in an evening than I do in a month! Just a note, I think you'll have to go with thinner clamps on the drive shaft boot - the ones you've installed may slide off or cut the boot. You knew we'd spot this.
  20. backdrifter

    backdrifter Wannabe rider

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    I'm not normally that productive. If I were, this project wouldn't have taken me as long as it has!!! :eek1

    Good eye on the hose clamps. They seemed a little big to me too, but they tightened down and seemed OK. I'll leave them be for now. I'm compiling a list of all the last stuff I'll need. Once I have that, I'll place another order with BMW Hucky. I'll put the proper hose clamps on my list and will swap them out soon. Thanks!

    I think I overdid it last night and burnt myself out. Consequently, I didn't feel like working on it as rigorously today. I installed the petcocks with new strainers and ran the fuel lines. I had used cheap fuel line from Autozone last time, this time I got the good stuff from BMW Hucky (on the bottom).

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    I also installed the air inlet tubes, so now I have theoretically functional air and fuel delivery systems!

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    That's all I've got for now. I should be back tomorrow with a vengeance though! :evil