Ignition Switch Cover Dilemma

As I was installing the ignition switch cover on the headlamp bucket, I realized that the little brass post for the plastic slider spring was missing. Since I had bought the new (used) headlamp bucket on ebay, I still had the old one. The original still had the brass fitting attached, but as it turns out, the fitting (right) was riveted into the bucket and was not reusable.

Long story short, I needed a quick fix. I broke apart an old spark plug (left) and snipped off the end, just below the washer-like lip pictured. Then, using an extra washer inside the bucket and another one on the outside, I had a new post! I used a little blue Loctite to secure it in place. And the fix is hidden from view by the chrome ignition switch cover.

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.

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!