Wiring Harness

Swingarm and Motor Removal

Today I turned my beloved Airhead into a heap of metal, wires, nuts and bolts. Follow me on this heart-wrenching, yet hope-inspiring journey as I venture further into the belly of my tamed beast.

I started out by removing the headlight. Seemed as good a place to start as any. Looking at the photo it kind of brings back memories…..

I managed to rip the wiring harness out (labeling all the important bits), all the while being reminded of the last time I monkeyed with this wiring harness.

Next I knocked the old bars off. I’ll be able to throw these away, as I have a nifty set of clipons. If anybody wants them, email me.

So we pop the boot back by undoing the clamp. These bolts use the other end of your 10mm wrench (the 12-sided part) that you don’t ever use. You’ll probably want to step on the break while you crack these guys loose. ALSO.. BMW recommends you do NOT reuse them. Get new ones.. Capital Cycle has them.

Next I threw a block of wood under the final drive and then set about dropping the rear suspension. It seems like I noticed something important during this step and made a special mental note to say something about this part here.. But I think I’ve thrown the mental note in the can… Sorry.

Now to remove the swingarm. You will need a special 27mm socket from BMW. This socket can be ordered from any BMW Motorcycle dealership and most online BMW parts stores. I’m not certain on the price, but I think it’s in the ballpark of $4,999,999.99……. OR you can just do what I did and use your nifty angle grinder (the one you bought because I pressured you into it in previous posts) to thin the surface around the 27mm socket you’re about to go buy from AutoZone.. You will also more than likely need to flatten the surface of the socket… This will fit into the swingarm tube nicely.

Next you’ll need to arm your ratchet with the longest extension you can find (I’m not sure why I did that) and a 6mm allen wrench. This will be used to remove the swingarm bolt. I know.. you thought you removed it when you removed the two nuts with your newly-fashioned swingarm socket…. but now you have to remove the bolts that the nuts were hanging on to. Don’t question the German engineering. Once these guys come out, you can remove the swingarm.

OH, OH!! I remembered that thing I was going to mention earlier….. I forgot to disconnect the brake linkage from the final drive. I removed everything holding the swingarm and then kept wiggling it trying to remove it, and it wouldn’t come. I eventually realized I’m an idiot and removed the spring-loaded nut holding the linkage connecting the brake lever to the final drive brake actuator. THEN, it will come off.

Next, I had a friend come over, and we pulled the two motor mount bolts and muscled the Boxer Beast over to the workbench where it will be made better, faster, and stronger.

You DID get that angle grinder right?

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Sunday, November 21st, 2010 BMW Cafe Racer No Comments

Come on baby light my wires…

This post revolves mainly around the much-needed electrical work that has been patiently awaiting my attention. Through the use of secret internet channels (ebay) I managed to procure a headlight, left control assembly (horn, lights, indicators), right control assembly (run switch, starter button), and a big fat wiring harness. I still need to find a throttle and master cylinder / break lever assembly. But that’s another story.

As you can see the headlight is killer. It looks about 1,000,000,000^10 times better than that weird street-fighter thing that was on there.

So I’ve been carefully (but violently) ripping all the old wiring out. The old harness was chopped up to bits. Most of the connectors were cut off near the front and there were random wires and whatnots connecting the various doodads that should never have made it onto this bike.

As I went I made note of where things go to speed up the process. I also had a wiring diagram found at http://bmwmotorcycletech.info/R65Schematic.htm which proved invaluable.

New harness installed and new controls connected.

So that’s it. Of course the process took a minute or two. There were some confusing moments. And I did manage to blow at least one fuse before the end of the day. But In the end I had a bike that 100% working lights, and an actual starter button… did I tell you what I was using to start it before? Push button with one wire clipped to the battery and the other clipped to the starter solenoid.


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Saturday, June 26th, 2010 BMW Cafe Racer No Comments

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