Grounded by a Lost Wedgie

[montmil]

There's a current Tech Section thread about a missing clutch cable's barrel -the small bit that captures the cable's soldered nipple and is a pivot point within the control lever. Newish owner had an issue that was quickly resolved when the missing cable barrel was discovered. A learning experience regarding all Airheads.

I'll share another small part that is easily lost or, perhaps, is already missing thanks to a PO. Either way, without this mysterious little part, it may result in a possible loss of control while riding.

Notice the small wedge listed as #5 in the diagram. This small triangular bit of steel is what locks the control housing/lever perch to the handlebars. There is one machine screw that snugs the housing to the handlebar. Without the wedge installed, the aluminum 'ears' that form the housing's pinch bracket can be broken, resulting in the entire control assembly rotating about the handlebar or a worse case scenario, falling off as you properly apply a counter-steering push as you enter a sporty right-hander twisty.



This is a photo of the BMW NLA wedge. Excellent photo showing just how small this part is. You can well imagine not even missing it should you not know of its existence. Think changing out a handlebar...
   Fortunately, Bob's BMW http://www.bobsbmw.com/ sells a German-made repop for a healthy $10.00USD. I thought about making my own until I noticed the serrations on the curved face that bite into the handlebar. The Bob's Wedgie is part #32721232929R. Other dealers possibly may have these.



The only photo I could locate that shows where the wedge in installed is this nasty control housing offered on eBay. The white arrows indicate the install position. Note the flat areas for the wedge plus the alloy pinch ears. The fracture usually occurs to the ear under the machine screw's head. The BMW OEM wedge has a rounded notch that is captured by the machine screw, holding it in position during the tightening sequence. BTW, a new clutch-side handle unit is $89.00USD.



I do not have a handlebar housing unit that rotates but I plan to check all three Airheads just to be sure. I have a couple Wedges in the shop. All I have to do is find them.

[marcmax]

The darn little critters can jump too. If it falls out when removing the perch, AND if you find it, it will be at least 10 feet away.

[decorn33]

I checked out Bob's. The wedge is now listed as "AE" - no longer available.

[Tony Smith]

Monte.

Why do you do these things to me!
 
I had to look last night and of course, my R65 clutch lever perch does not have one. I know the R100 does not and given that I put a new perch on the R65/80 last year I am certain it doesn't.
 
Out of curiosity I turned out the broken parts box and checked the R65 perch I broke trying to force it over a Renthal bar and the perch that came off the r65/80 (herself decided to change it for cosmetic reasons) - no wedgies found.
 
If the R100 ever had one, it would have been lost in 1979 when I pulled it apart to remove the fairing boots to let more air in. Nothing bad having ever happened since then I think I will pass on spending $30 plus postage to obtain a part whose need is doubtful. This strikes me as a BMW "the master link clip on a timing chain must be fitted against the engine block" issue.

[Barry]

I still have the original wedges. I suspect all they do is allow the perch to get a good grip on the bars at relatively low levels of torque on the clamping screw. I tighten mine by hand using only the short end of the Allen key to limit the risk of stripping the threads and the perches never move.

[MikeFossl]

I don't see anything like it on the right. :-?

I'm still hoping to pull the wedge in order to fit my 7/8" handlebar. :-/

[montmil]

... I'm still hoping to pull the wedge in order to fit my 7/8" handlebar.

The tough nut to crack attempting to use 7/8-inch diameter handlebars is the throttle's twist grip tube binding. There was a good discussion on this topic just a couple weeks ago.

[MikeFossl]

The throttle twist grip tube just barely slides on the new 7/8" bars that I have.  I figure with a bit of "polishing" I can get it to work.

The clearance on the perches seem more problematic, hence my search for the wedges.

[montmil]

I checked out Bob's. The wedge is now listed as "AE" - no longer available.

I also saw that 'AE' notice on Bob's R65 fiche page. Give 'em a phone call and reference the part number with the 'R' suffix. The wedge is an aftermarket item produced in Germany. Kinda remember I found it on an R80 fiche... maybe. It's also on the Max BMW site but goes for $14.00 rather than $10.00 from Bob's.

Check section 32-Steering:
http://www.maxbmwmotorcycles.com/fiche/DiagramsMain.aspx?vid=51897&rnd=04282014

[Matt Chapter]

I have to say that I don't think this piece is in the '85 and on assembly.  Seems like the assembly comes together in a different way if I remember correctly.

[Bengt_Phorqs]

Check with Hans Lowe at BMWhucky.com.  He has the wedges in his catalogs and I've had good luck dealing with him.

32 72 2 072 223             wedge for Magura grip       1970 on       $ 13.00

And my experience with a 7/8"OD handlebar is that you will have too much interference on the throttle side, even with polishing assuming you are using BMW OEM controls.  A 7/8" bar is .875" OD and the 22mm is .866.  

[montmil]

The clearance on the perches seem more problematic, hence my search for the wedges.

The wedges used on the original <1984 Magura handle bar unit are designed to keep the pinch ears from closing up too far and fracturing the aluminum. They are not designed to force the components open.

22mm and 0.875 inch:  Mars and Venus

I just received a complete left-side handlebar unit for the '83 R65. It's from a 1991 R100 and shares the same current BMW part number as is listed for the 1983 R65. No wedge required. Updated Magura production that supercedes the earlier wedge-required units.

[tvrla]

You can tell if yours needs the wedge if the edges of the slot look like the one pictured. The newer perches don't have the wedge shaped slot.

[Kelvin]

Good thread: forewarned is forearmed!

I recently replaced the RHS handlebar mount on my R65LS: the old mount included the wedge, the new one didn't require it. The difference is visible in this photo (old on left, wedge at bottom of pic).