More Wiring

With the signals working, the next step was to try to clean up the wiring a bit more. 

With some fiddling with wires, we were able to produce a spark, so at least all of the ignition components are in working order.  Next we need to ensure the switches work as they should.

 The next step was fabricating a proper muffler mounting strap.  A fairly straightforward process, but it did require some accurate measuring and drilling to make sure the two mounting bolts lined up properly.

Next we began the process of fitting the front seat mounting studs.  Like the rear battery tray, we are going to weld in some shouldered m6 nuts into the frame rails, and then fix the front end of the seat in place.  The holes were drilled and the nuts put in place; Mr. S will come in on another day and do the welding.






Finishing the wiring will be the next step.  Tedious, and in fact Mr. Sheppard came in on his own a couple of evenings to work on things.  Really, at times a one-person job due to the cramped nature of the bike. 

Signals next

We snatched victory from the jaws of defeat.  After spending most of the session flicking the turn signal off and on, we came to the conclusion that the turn signal relay was not the right type for our application.  We got a "click" out of the relay, but no lights.  Not knowing a lot about relays, we guessed that there might be too much resistance in the relay unit, and decided to try something different. 

While Mr. Sheppard rooted around the boxes of spares for another relay, the tailight mounting bracket was modified to accept the turn signals.

With the signals then mounted in the bracket, and everything re-attached with the replacement relay (over 40 years old), we got ready to test again.  Note the size of the turn signals.  These are DOT approved.  Yes, very large, but we don't want any hassle when we go to get the bike saftied.  The new owner may swap them out for something smaller...
The student in the pic is grounding out the terminals on a bare part of the frame.

Left.... got it!

And the right one works as well!  Next up, ignition system.  We will search for that elusive spark, and then go about properly bundling and connecting the wires in the harness.

Slow and Steady Progress

The April 2 session saw some more tangible progress for the bike project.

A "new to us" (used) exhaust system was sourced which works better with our cafe rear sets.  It is a MAC 2-1 system.  We will need to fabricate a muffler mount, but everything appears to work as it should.

Next we went about tacking more of the custom wiring harness.

Using a heat gun to heat-shrink tubing once connections have been made.

Soldering connections.  Always nice to have a second pair of hands.  Watch out where the melted flux falls, as it can be corrosive on painted surfaces.

Fitting proper battery terminal connections, as well as prepping the connectors that fit into the fuse box.  Need to get everything water-tight!

Tail/running light.

Brake light.  Whoo hoo!

To date, we now have working headlight, tail light, brake light, instrument light, and horn.

Next step is the turn signals, and finally the stator/rotor/alternator/ ignition system.  Gotta get that spark!

Next cafe session is April 16.