Due to a lot of cracks in the top middle fairing panel that surrounds the headlight and the fact the upper fairing bracket had both tabs broken that secure the strap that bolts to the steering head, I wanted to check the frame to see if it is straight. I borrowed a frame jig from a long time BMW mechanic who is now retired and used it to see what’s up. The good news is the frame is straight “enough” for my purposes. 🙂
I wrote up how I removed all the body work on this bike. I discovered a broken upper fairing bracket that was held on with only a hose clamp. There was a broken plastic boss with a threaded insert and numerous cracks and other damage to the fairing panels and side covers. I repaired all of them except for the top center panel that goes around the headlight. The damage was significant with a multitude of hairline cracks and I opted to buy a used panel rather than risk cracks showing up in the paint work after I tried to repair it.
I picked this bike up in April 2016. Finally, on September 1, I got started on it. I had to finish up work on the 1975 R75/6 “S” update and completed that in July. I’ve put about 600 miles on that bike and its running well. You can see all the work I’ve done on the R75/6 here:
I made a short video to show the routing I used and where the front turn signal, neutral switch, voltage regulator, starter relay, coils, Dyna III electronic ignition, oil pressure switch, neutral switch and rear tail light/turn signal wires go.
It includes links to two other write-ups: The first describes the wiring connections to the diode board, alternator, points, and starter motor when I replaced the timing chain; The second write-up shows the details about the circuit board connection areas inside the headlight shell and how to connect the right handlebar switch inside the headlight shell.
I had to replace this switch and decided to document “what wire goes where” inside the headlight shell on the circuit board and to the ignition switch and headlight relay.
I also explain how to map information found in various wiring diagrams to the labeled areas on the circuit board. There are some places where things got confusing for me in going between the various published wiring diagram(s) and the circuit board inside the headlight shell, so I hope this material helps others avoid being confused.