Electrical Components 2

Here is the view of the right side showing more parts, including one of the two original Bosch ignition coils (left) and the regulator (right). As far as I know, these components (as well as the starter relay in the last post) are all functioning well, so they will just be removed and their contacts and surfaces cleaned.

Electrical Components 1

I took many pictures of the electrical components hanging on the frame below the fuel tank. In this view of the left side, you can see the starter relay, parts of the frame wiring harness and the engine harness entering the top of the engine.

I have decided to replace most rubber parts and wiring harnesses on the bike due to age or wear. In this shot, those include the rubber tank support (16 11 1 230 030), frame wiring harness (61 11 1 354 674) and engine harness (61 11 1 350 636). The harnesses come with some rubber grommets in place, such as the one seen at the top of the engine block. Some components, such as the air intake hood seen at lower right, will clean up nicely and do not need to be replaced.

I Fought the Lock and the Lock Won

The fork lock is one of several items you'll need to remove from the frame before it can be powder coated. This is what mine looked like before I attempted to remove it...pretty harmless, huh? The problem, of course, is that I didn't have the key. If you're in the same boat, do yourself a big favor and read Duane Ausherman's article on fork steering lock removal. I didn't know about this article until it was too late, and I'm too ashamed to post the photos of what the lock looked like two days and three drill bits later. It wasn't pretty.

Taillight Assembly

Here's a view of the taillight assembly as I was removing it from the bike. This is typical of the photos I've taken for all electrical components. If you need to, you can also make a diagram of the connections for easier reassembly.

Electrical Harness Straps

Important to note or photograph during disassembly are all the locations that electrical harnesses (as well as any other cables, etc.) are strapped to the chassis. Remember, there's a reason they're strapped where they are!

Front Stud and Pushrod Seals

Like the rear engine stud, the front stud on my bike also has a dual function. It is the mounting point for two of the crash bar clamps, as you can see in the lower left of the photo.

As I was disassembling the bike, I also noticed another problem...the two leaking pushrod tube seals above. An inspection showed the same problem on the other side. That's what happens with seals that are almost 40 years old!

Rear Engine Mount Stud

There are two engine mount studs holding the engine in the frame. The longer of the two is the rear stud, the end of which is also the mounting point for the driver's footpegs and exhaust clamps.

Starting to Strip the Bike

The first things that I removed from the bike were the carbs, fuel petcocks and the gas tank. Then came the fenders, crash bars, mufflers, rear shocks and taillight components.

At this stage I also removed the battery holder brackets and removed the top two screws holding the sub-frame on. The sub-frame is resting on the back tire until I remove the wiring harness that runs through it.