'79 Air filter installation tips?

[AlfromNH]

I'm attempting to install the air filter and housing. A '79 with the old-style aluminum castings. Like this(not my bike):
http://motorbike-search-engine.co.uk/classic-bikes-2/1979-R65.jpg

Is there a trick? The right side has to go on first, in order to access the nut that holds it on. For removal, the Clymer manual says to remove the boot between the air filter housing and carb on the left side, then remove the filter housing. Assembly is the reverse. But the connecting boot is plastic, and not particularly flexible. Do I just wedge it in there?

[Lucky_Lou]

Fit the far side(as in photo) clamshell to the mounting bolts after threading the oil breather pipe, then offer up the filter  fit the near side into the clip mounting on the gearbox and engine bolt. The long screw which clamps the two pieces together can then be located by putting your fingers in the outlet pipe to guide it into the other half, it is a bit awkward due to the breather pipes but you should manage it.
I don't know if there are any images but have a look in the Haynes manual  page 38.
Lou

[AlfromNH]

Got it. The trick is to slide the rubber coupling all the way onto the plastic boot. Then put the boot in place, and slide the coupling over the housing flange. Very simple  


And another important lesson: the choke lever must be mounted to the housing before the housing is assembled. The housing is not threaded for the lever assembly screw, it uses a nut on the other side.

The number of jobs on this bike that I've done more than once... It's a good thing I'm not being paid by the hour!  

[Barry]

I put a little silicone grease on the inside of those air filter rubbers to make it easier to slide then down onto the plastic elbow.

The choke lever mounting screw got me the first time too.  

[montmil]

How many noticed the nice Heim-jointed, adjustable shift linkage on Al's bike?

I have one on my R65s and I'm making up one for the R100S. So sweet, they are, and much better shifting than with the "bent paper clip" OEM job.

[Barry]

Al,

Looking again at your picture things don't quite line up perfectly. Mine doesn't either so don't worry that's normal. I shortened the engine to carb rubbers a little which helps although you have to be careful as the enricher cable ends up fouling the dipstick. I was concerned as much as anything about not having a significant gap between the engine stub and the carb for fuel to pool in.  I didn't completely close the gap as I thought it might be intended to prevent transfer of vibration through metal to metal contact.

[marcmax]

I changed my R65 from the flatter black airbox to the aluminum clamshell style because I like the way it looks. I had a heck of a time getting the air filter plastic "elbows" to line up until I learned they are left/right sided to compensate for the cylinder offsets, completely different angle in the bend. The newer airbox has the offset built into the airbox itself. Once I got the right "elbows" it slid right into place.

[nhmaf]

I get ready to do some cursing everytime I have to work on my '78 - there are a few tricks - and you've figured out the most critical ones now!

[AlfromNH]

Everything aligned pretty nicely. There was enough slop in the various connections, and all the clamps were loose in the photo.

I agree- I like the looks of the metal castings vs the plastic airbox. And I like the "choke" lever setup: fewer cable running to the bars.

I got that shift linkage in a "grab bag" of parts from an eBay seller I built a relationship with. I sent a pic of it to Justin, he said it looks like one of his early ones. I have to admit, when I pulled the rubber boot of the original linkage I was quite disappointed to see BMWs use of plain wire. I think that's why they covered it with a boot