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PROGRESS REPORTS
Reassembly (3)
This report is for the electrical
wiring and lighting. When I got the bike it had maybe half a dozen wires - the
bare essentials necessary to run the ignition, head/tail light (no hi/lo beam),
and the brake light. Everything was hard-wired point-to-point with no terminal strips.
I purchased a reproduction wiring harness that had the cloth-covered wire and the
asphalt loom. It was pretty accurate and complete the way it came, but I had to
make some modifications because of the way I wired my switches and because I have
an alternator and solid-state regulator instead of the generator and cut-out relay.
In the end though, it looks more true to the original.
Wiring - Front Terminal Board
I couldn't find a front terminal board so I improvised and made one out of some perf board from Radio Shack. I bonded two layers together to give it some added strength and then used #10 stainless screws for the terminals. Keep in mind that this area will be covered up with a stainless fork tin panel.
Wiring - Left Front
This shows the left side of the front fork. The relay is used for the hi/lo headlight beam. The headlight/taillight are turned on when the ignition switch is turned to the 2nd position, but I needed a way to actuate the high beam. I mounted a switch on the handlebar but was concerned because it did not appear that it would handle the headlight current. So, I decided to use the switch to actuate a relay that would, in turn, actuate the high beam on the headlight.
I still have to make some sort of board to mount the relay and flasher on so that they are not just rattling around inside the fork tins.
Ignition Switch
Besides the connection on the switch itself, there are also some connections that just join two or more wires together. I'm not really sure how that was done originally but I used some plastic wall anchors and inserted them in the dash mounting plate then used #10 sheet metal screws to secure the wires.
Seat Post Terminal Strip
I did find a seat post terminal strip on eBay - like I said before: there were no terminal boards on it when I got it.
Wire Looms
Just showing the routing of some of the wire looms. I haven't checked the fit of the gas tanks yet so I may end up relocating some of these if they interfer.
Horn
I know this is not the proper location for the horn. This is a temporary setup - I plan to eventually install a trumpet horn. I just wanted to get something on it to make it legal (it didn't have a horn when I got it).
Lighting - Front
View from the front showing the new headlight, spot lights and turn signals.
Lighting - Front Turn Signal
Showing the installation of the front turn signal. I plan on changing this because I don't really like the way the mounting stud and wire are sticking up like that. Maybe I can bend the bracket at a right angle so that it is hanging down, then mount the turn signal so that the mounting stud and wire are pointing toward the center.
Lighting - Rear
Tail light and rear turn signals.
Lighting - Rear Turn Signal
Close-up of rear turn signal mounting.
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This page last updated on December 18, 2006
©2003-2006 David Remelts
