The New And Improved Unofficial R65 Forum V2
General Category => Chit-Chat => Topic started by: montmil on September 28, 2012, 06:48:40 PM
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It's been a few weeks since the R100S moved into the garage. I'm already making a few minor alterations; a couple ideas things to make it more mine.
The original builder, prior to powder coating the chassis, cut off the side panel mounts. I don't so much mind that but from the battery's back half, the visual is a bit cluttered.
So, from some .090 sheet aluminum, I have made flat side panels that fit into the "V" formed by the frame. Just enough closure to clean up the wiring and the Battery Tender connection. Now need to clean, prime and paint 'em a glossy black.
Bengt Phorqs reminded me that the bike did not have an under seat tool tray. Those are handy so Bob's BMW sent me a brand new one. All I had to do was drop it in place. Oops...
Attached to the left-side upper frame rail resides the small Dyna ignition control unit. That's gotta find a new home so the tool tray will fit. Ultimately moved the Dyna ICU to the lower tube on the R100's backbone; adjacent the starter relay and in an area of cooling air. I figured the cooling fins on the Dyna meant something.
The tool tray now fits. I added to the seat bottom a couple of 3/16" thick dense foam pads to secure the tray and stop the rattles of plastic against steel. Time for a road test.
Well, slap me, the starter will not work. Checked the handlebar kill switch, the battery, said a quick prayer and tried again. Nothing.
Opened the headlight shell and checked fuses. Cleaned the already clean Euro ceramic fuses. BTW, you need small hands to reach the back of the bucket. Still nothing.
Checked in with da 'Bum and began following his "starter will not function" checklist. Of course, I was concerned that moving the Dyna unit adjacent the starter relay might be the problem. So removed the one machine screw anchoring the starter relay and its mounting block for a look-see.
What the heck? Besides being very dirty and needing some corrosion cleaned off the relay spades and the 'block', I immediately noticed a broken and detached wire. This may be my problem...
(https://bmwr65.org/smf/proxy.php?request=http%3A%2F%2Fi196.photobucket.com%2Falbums%2Faa1%2Fmontmil%2FBMW%2520R100S%2FRelay02.jpg&hash=bc7edb774e962ce5108cdb56a785468db5504762)
What a nasty looking electrical component. The broken wire had evidently been shedding copper strands for some time. See the totally vacant female spade terminal? And note the toasted end of the insulation where a very few strands were carrying a fairly heavy electrical load.
Used a BMW relay block replacement female spade from my collection of OEM wiring harnesses. Worked over the relay and got all the male spades shiny and coated with dielectric grease.
(https://bmwr65.org/smf/proxy.php?request=http%3A%2F%2Fi196.photobucket.com%2Falbums%2Faa1%2Fmontmil%2FBMW%2520R100S%2FRelay01.jpg&hash=90be09b45cd3fe238cb4bcbed5045fac951ab7d0)
Note the heavy gauge red wire. That's typical of every terminal in the starter relay assembly. Still have some cleanup work to do but I just had to see if the loose wire was the problem
With the fuel tank off the bike, the carb bowls were all I had for a test, but with ignition on, I hit the starter button and the engine lit off.
For me, that's proof again that most Airhead problems are simple. You just have to follow a methodical path and find the, usually, simple fix.
No test ride this afternoon. It's finally raining.
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Yeah, these things are basically simple! Aren't they? And there's something so satisfying about fixing them.
That's really odd the PO removed the side cover tabs. I've not run into that one before! Seen a lot of other things, but not that one. It'd be easy enough to fabricate new ones and weld them in. Probably wouldn't even mess the paint up too much.
What did you use to clean the electrical connections?
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... What did you use to clean the electrical connections?
I gathered a plethora of options: 3M Scotchbrite in 1000 grit, a small brass bristle brush, 400 grit Wet-Dri, CRC spray cleaner, some chisel-carved-to-fit craft sticks, couple of tiny flat-blade screwdrivers...
Basically, anything that would reach, scuff, clean or polish the terminals. Labor intensive but as you said, 'Spokes, "so satisfying."
We're still getting some rain forecast for all day Saturday. Pretty Wife is headed to Ft Worth -aka: Cow Town- to meet her sister for some day-long "chick event". Mongo will enjoy a good day with his Beemer Brood. [smiley=clap.gif]
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I've found Wright's Copper Cream to work well for cleaning connections. I may have to try their liquid cleaner to see if it's easier to use on hard to reach places like the female connections. I've used a tooth brush with a teensy dab to clean connections - doesn't scratch the plating if it has any, and is quick and easy. I've tried other things like tarn-ex (can't recall what else), but wasn't particularly happy with them. The Wright's is great stuff!
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I removed my side panel mount for my Cafe Racer...
On a standard bike, the lack of a side panels does not look right.
But on a simplified bike, a cafer racer or bobber, they are superfluous.
They are there to cover unsightly shit up. If you remove the shit, you do not need to cover it up.
I am looking forward to how you progress Monte.