1973 BMW R75/5 Rebuild: Install Wiring Harness & Electrical System

It’s time to take a big step forward on the project and install the electrical system. Here is the write-up on this part of the project.

I removed the wiring harness and all the peripheral electric components so I could have the frame powder coated.  I documented some of that disassembly in this write-up:

At this point, with the exception of the rear fender and the attached turn signal and brake light assembly, I have everything installed in the frame that the wiring harness connects to. Thanks to a lot of pictures I took during the general disassembly of connection details and wire routing, putting it all back together was pretty straight forward.

Here are a couple pictures for the many I included in the write-up.

Broken Wiring Harness Sheath

Broken Wiring Harness Sheath

Corroded Lug on Starter Relay Wire to (+) Battery Terminal

Corroded Lug on Starter Relay Wire to (+) Battery Terminal

Engine Wires Attached to Starter Relay

Engine Wires Attached to Starter Relay

Horn Assembly

Horn Assembly

Horn Mounted

Horn Mounted

Attaching Headlight Shell Gaskets

Attaching Headlight Shell Gaskets

Mounted Headlight Shell

Mounted Headlight Shell

Threading Main Wiring Harness From Headlight Along Frame Backbone

Threading Main Wiring Harness From Headlight Along Frame Backbone

Right Control Perch Switch Cable Routing

Routing of Right Control Perch Switch Cable From Headlight

Starting to Pull Rear Frame Wiring Branch Through Rear Frame Tube

Starting to Pull Rear Frame Wiring Branch Through Rear Frame Tube

Routing Neutral Switch & Oil Pressure (Through Hole in Frame Gusset) and Rear Brake Light Wires (Under Battery Box)

Routing Rear Brake Light Wires (Under Battery Box)

Transmission Neutral Switch Wire

Transmission Neutral Switch Wire Routing Underneath the Frame

Connect Battery (+) Cable to Starter

Connect Battery (+) Cable to Starter Motor Solenoid

Smoke Test Success - It's ALIVE!!!

Smoke Test Success – It’s ALIVE!!!

What The Project Looks Like With Electrical Wiring Installed

What The Project Looks Like With Electrical Wiring Installed

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