Hi LC,
I've been following your project and learning a lot from your experience. It's great that you've taken the extra time to document all of this. Seeing the bike stripped down is really helpful. If you don't mind, I've got a couple questions:

--The negative side of the battery is connected to the engine though one lug, is that correct?

--In the wiring harness, does the motronic have a direct wiring connection to the battery via its own wiring?

--In the photo of the exhaust below, what is the red color on the cat/muffler? Also, I see the blueing in the lower left corner of the cat and at the O2 sensor neck I have that on my '04RT. I guess that's normal, but wonder if the heat is high there due to mis-fired fuel igniting.

--What type of O2 sensor do you plan to mount?

Thanks again,
Roger

Don't know about the other stuff, but the blue color is quite normal. Caused by the exit of gasses from the catalytic convertor.

Correct. Here is a picture of the connection point I took during tear down. It is under the battery tray.



No it does not.


The red is the reflection from the incandescent lighting in the shop. The blue is normal for the pipe.


A 4 wire Bosch, part number 13474.

Thank you. Lots of things here that I wouldn't have seen for a long time till I do my spline lube. RB

The speedo cable seems to be too short. I do not have the old one around to make a comparison, but the new one measures out to a little over 1000mm.

I cannot turn the bars to the right without the cable dragging across the left caliper.

Is the cable too short? What is the stock spec? Could it be the result of the new Ohlin struts? The struts as the root cause seem improbable to me, but I thought I'd throw it out there.

As a workaround I went ahead and ordered the cable for the GS--it is 40mm longer and should fix my problem. I think...

Comments and suggestions are welcomed.

Cheers!

Inch by inch...

Hi Limecreek,

Your speedo cable is likely OK for length - what appears to be wrong is that it is leaving the speedo drive unit at the 5 o'clock position - it should be between the 2 and 3 o'clock position.

This is likely caused by the speedo drive unit not being correctly located on the lug in the fork leg.

As pointed out, you seem to have the speedometer drive clocked incorrectly. While mine is a R1100RT, I'm pretty sure it is the same as yours, though not nearly as clean. There is a tab on the fork and two tabs on the drive. The drive tabs slip between the fork tab.

I agree with Ced and Eddd. What says Ted? and Ned?

Guys - yes you are all correct.

Instead of referring to the service manual I aligned it in a way that made sense to me. Intuitively it made sense to align the speedo drive behind the lug on the fork leg to prevent it from rotating in the direction of forward wheel travel--counterclockwise.

So much for my intuition.

Which manual are you using? Haynes? BWM? other?