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I prefer to powder coat the frame and small parts, Powder is much more durable than paint and if done properly it looks the same as paint.Our powder coated frame and forks are assembled and the power train is installed, We like to get the engine in the frame first, then assemble the rolling chassis but either way works, use masking tape to protect the components as they are going together. All sheet metal parts get a base coat clear coat with hand applied pinstripe over the clear. If you don,t have an original on hand for reference take several photos of the stripes before stripping so your striper will know how to apply the stripes, its almost guaranteed he won't get them right unless he has a good example to copy.

We replace front and rear swing arm bearings and we install a new set of taper roller bearings in the fork neck. A new set of European low handle bars and all new cables and all new rubber parts. We are also using our stainless steel bolt kit on this bike, they look great and make assembly time faster. If you are going for a concurs 100 point restoration you will want to use all the original bolts with new cad plating.


Since this is not a technical article we will breeze thru the electrical details. The BMW wire harness is super simple it only contains about ten wires and they are color coded. Start at the headlight and work your way back, the /2 owners manual has an excellent wire schematic in case you get lost. Its best to photograph the wire harness before disassembly so you know the correct routing, this is not laid out in any manual. We had a good terminal board but the wire harness is being replaced with a new one. The terminal block for the tail light usually gets rusty, a new one is cheap insurance against future problems. I hate to see nylon wire ties on a vintage bike, All visible wire ties should be like the original metal strap ties.Bar end blinkers by Hella are a nice period accessories and a unique item for German bikes, consider a set at this time. Your battery should have a removable lid like the original, stay away from the Yuasa battery, it works fine but looks like crap.

We only need to clean and lubricate the speedometer, new chrome bezel rims are available and can be crimped on by hand with a screw driver. I do not recommend you zero the mileage, its better to preserve the history of bike by keeping the odometer mileage original to the bike.

   

Next week in episode 7:
We touch on the chassis details and hit the home stretch.

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