I’m converting this bike from and RS to an RT model, so there are some changes associated with the RT model, but the electrical system changes are limited to changes in cable lengths for the handlebar switches.
This document references other documents previously published as well as containing new material.
The idea is to consolidate information about how I install the electrical system on the bike in one place. I also include the results of my testing of the electrical system, the problems I found and how I fixed them. I hope this is helpful.
On this model/year bike, it’s critical to shim the oil filter canister correctly to avoid loss of oil to the engine. I show how I do that. I also show how I install the oil cooler, thermostat-oil filter cover, and the shims and o-rings to properly seal the cover and oil filter canister.
I installed the transmission in the frame, mounted it to the engine block, connected it to the drive shaft, assembled the clutch throw-out mechanism, attached the speedometer cable, the neutral switch wiring and the foot shift.
I also installed the handlebars, perches, switch assemblies and routed the cables. Since I am converting the RS to and RT configuration, the switch wiring and cables are RT length.
This is the second time I have worked on rebuilding an airhead transmission. That should make it clear that I am an amateur, not a professional, when it comes to doing this work. I would not attempt to rebuild a transmission unless I have access to experienced, long time, airhead mechanics. I’m very fortunate to have access to three of them. And, I plan to continue rebuilding transmissions on my own projects, so the considerable investment in tools will get amortized over the future projects.
NOTE: I would not recommend that you rebuild your transmission unless you have completed multiple bike rebuilds, have invested in precision measurement tools and specialized transmission tools, and expect to rebuild multiple transmissions. The cost and risk are too high if you just plan to do one transmission. I would recommend you have your transmission rebuilt by a reputable builder such as Tom Cutter at Rubber Chicken Racing Garage in Pennsylvania, Matt Parkhouse ([email protected]) in Colorado, Bob Clement at Bob’s Motorwerks ([email protected]) in Montana, and Bud Proven at The Nickwackett Garage in Vermont.
This transmission has over 83,000 miles on it. That said, it was in good condition when I had the parts inspected by an airhead mechanic. So that’s a good thing.
I show how I route the main wiring harness after I installed the headlight shell. Previously I replaced the main harness with one from Euro MotoElectrics.
