R65LS Assembly Questions

[Red_Hen]

Hi Gang,

FINALLY - got the bike home yesterday.  Need help figuring out where the long black wire goes with two eyelets - it has a silver BMW label on it.

Think we routed the carb / choke cables incorrectly - thinking they go under the frame pipe, not over it.

There is a picture of my ignition switch - any suggestions on RX to mate correct wire with pole on (5) connector switch appreciated.

In case pics don't show up here, please click links to see pics:

http://kentuvman.shutterfly.com/92#90

http://kentuvman.shutterfly.com/92#92

http://kentuvman.shutterfly.com/92#91

[bruce_launceston]

I don't recognise the black wire but the throttle and choke cables should run below the line of the frame backbone tube on the left side. They should be loosely held in place with cable ties so that they can move if necessary.

[Red_Hen]

Thanks, Bruce - thought they were not placed right.

The long black wire - it's obviously a ground wire - does it come off the engine?  I know (think)  it came off the bike.

[Mike V]

Ken,

Maybe these will help?

http://s428.photobucket.com/albums/qq8/gruntyman66/81%20R650%20Restoration/Cables%2008-09/

[Red_Hen]

Mine is a 1982 R65 LS (Hans Muth)

Okay - I'm taking my time on trying to understand the "routing" of the throttle & choke cables.  I saw the pics Bruce & Mike sent from grumpy guy - my Clymer books is really vague - it makes reference to removing the old cables & pulling through the new cables with a piece of long string.  I believe the book  shows the choke junction box on the starboard side of the frame and the throttle junction box or tube on the port side - if any of you have changed throttle cables and can enlighten me, I'd really appreciate it.  

I asked about the long black wire with the two eyehole connectors on the ends - is it possible this is a ground wire for the brake light?  I seem to recall it maybe coming off of there when I tore here apart - I have to go through my pics again.

Last - the ignition wires that plug to a 5 pole ignition - if no pictures, what is the logic or process of elimination to figure which wire goes where?

[Bob_Roller]

Factroy ground wires are solid brown color .

[Red_Hen]

I'll have to keep digging on this one Bob - thanks.

I'm keen to know how to run the choke & throttle cables. . .

[montmil]

I'm keen to know how to run the choke & throttle cables. . .

Hey, Ken

Often, the throttle and choke cables extend beyond the 1-into-2 junction fitting, slightly different lengths appear to account for one cylinder being further forward than the other. It's a con rod crankshaft deal...

My throttle cable are under the main frame's backbone and then split off to the carbs. Shorter of the two pairs goes to the more forward carb. Longer cables to the aft carb. Try for smooth arcs and straight shots into the cable adjusters on the carb tops and enrichener.

Do not zip tie the cables hard against the chassis. A couple ties, fitted loosely to maintain the cable's position, will do fine. Test the cable routing by turning the handlebars full lock left and right. You'll want free carb and choke cable operations with no unwanted throttle inputs with the bars turned in any direction.

If the install looks right, it probably is.

Monte  

[Red_Hen]

Thanks, Monte

[nhmaf]

+1 on not making the throttle and choke cables tightly tied to the frame - they DO move forward and backward a bit as you turn the handlebars from lock to lock (try this and see) and you absolutely do not want them to bind or stick on anything during thise - otherwise you might get a carb opening up or closing down when you make a left or right hand turn.

I oriented mine so that one splitter is slightly ahead of the other, and both are more or less on the left side of the motor on top - longer cables reaching to the right side carb as it is slightly longer distance.   This keeps the cables away from possibly snagging on any of the electrical wiring on the right hand side of the frame under the relay bracket.

[Red_Hen]

Thanks guys - throttle cables re-routed and working!  Throttle snaps back as it should!  Getting excited.

Need to test the electrical and find out if everything is working - got some help on MOA forum.

Will install needle bearing Rob Valdez graciously mailed me  

will add fluids.  taking my time - hope to try and fire her up in the next couple weeks or so.