SJRoome
Registered user
Hi
About a year ago I upgraded the suspension on my 1989 R100GS with a new shock and fork upgrade kit from Hyper-Pro and I was very pleased with the result.
As we are having a sunny spell I thought it was time for a few more upgrades. Here is the bike when I started.
Here are a couple of boxes of goodies.
Once I removed the seat and toolbox you can see I have an Odessey PC625 battery with a first aid kit and a rucksack crammed into the gaps. Removing them you see one of the straps is not connected and has probably stretched over time.
Removing the battery straps and unscrewing the nuts on the battery terminals, negative (earth) first enables the battery to be lifted out. I removed the nuts securing the battery holder to the rubber mounts and the nuts securing the upper two mounts to the frame. On the right the power socket comes off the battery mount screw. Its rubber cover has perished.
On the left side the fuse holder twists out of the battery holder. Looking down you can see the wooden frame I made to secure the Odessey. Loose straps or not that battery was not going anywhere.
There was nothing about it in my workshop manual, but the battery holder was also fastened to the rear mudguard by a clip which I levered out.
Once I had it out I saw it was a standard car trim clip. I then removed the air filter and air filter cover to give myself more room. With some pushing and pulling the battery holder now came out.
Here is everything I removed and the tools I needed. You can see I used two ½ inch extensions to reach the nuts on the lower mounts.
Here is the first goodie from the boxes. A laser cut stainless steel battery holder.
Unfortunately it is too small for my Odessey 625 battery. I probably should have checked this before ordering it.
I have this example of German precision engineering in my vice and I am about to introduce it to a British hammer when a thought occurs to me. When did I buy the battery? Reference to my paperwork indicates that the battery is over 14 years old and the battery holder gets a reprieve.
I clean around the area where the old battery holder was with WD40. The battery holder drops in from above. I remove the perished rubber from the power socket and replace it with self-amalgamating tape. I relocate the power socket behind the battery and replace the nuts and washers with stainless steel ones.
The new battery holder does not have an attachment for the fuse holder. I consider fastening it to the rear mudguard but end up cable-tying it to a frame tube. I use two layers of 3mm adhesive foam between the tube and the holder to provide some protection from vibration. I replace the air filter and its cover.
As a temporary measure I refit the old battery transversely above the new battery holder. It just fits and there is also space for the toolbox if you remove the lid. The terminals are replaced with the negative (earth) terminal being connected last.
The finish on the adapter I made does not quite match the battery holder, but its only temporary.
Now what shall I get out next?
About a year ago I upgraded the suspension on my 1989 R100GS with a new shock and fork upgrade kit from Hyper-Pro and I was very pleased with the result.
As we are having a sunny spell I thought it was time for a few more upgrades. Here is the bike when I started.
Here are a couple of boxes of goodies.
Once I removed the seat and toolbox you can see I have an Odessey PC625 battery with a first aid kit and a rucksack crammed into the gaps. Removing them you see one of the straps is not connected and has probably stretched over time.
Removing the battery straps and unscrewing the nuts on the battery terminals, negative (earth) first enables the battery to be lifted out. I removed the nuts securing the battery holder to the rubber mounts and the nuts securing the upper two mounts to the frame. On the right the power socket comes off the battery mount screw. Its rubber cover has perished.
On the left side the fuse holder twists out of the battery holder. Looking down you can see the wooden frame I made to secure the Odessey. Loose straps or not that battery was not going anywhere.
There was nothing about it in my workshop manual, but the battery holder was also fastened to the rear mudguard by a clip which I levered out.
Once I had it out I saw it was a standard car trim clip. I then removed the air filter and air filter cover to give myself more room. With some pushing and pulling the battery holder now came out.
Here is everything I removed and the tools I needed. You can see I used two ½ inch extensions to reach the nuts on the lower mounts.
Here is the first goodie from the boxes. A laser cut stainless steel battery holder.
Unfortunately it is too small for my Odessey 625 battery. I probably should have checked this before ordering it.
I have this example of German precision engineering in my vice and I am about to introduce it to a British hammer when a thought occurs to me. When did I buy the battery? Reference to my paperwork indicates that the battery is over 14 years old and the battery holder gets a reprieve.
I clean around the area where the old battery holder was with WD40. The battery holder drops in from above. I remove the perished rubber from the power socket and replace it with self-amalgamating tape. I relocate the power socket behind the battery and replace the nuts and washers with stainless steel ones.
The new battery holder does not have an attachment for the fuse holder. I consider fastening it to the rear mudguard but end up cable-tying it to a frame tube. I use two layers of 3mm adhesive foam between the tube and the holder to provide some protection from vibration. I replace the air filter and its cover.
As a temporary measure I refit the old battery transversely above the new battery holder. It just fits and there is also space for the toolbox if you remove the lid. The terminals are replaced with the negative (earth) terminal being connected last.
The finish on the adapter I made does not quite match the battery holder, but its only temporary.
Now what shall I get out next?
