650 Mod's 78 Fighter Build

650mod wrote: So Christmas came in July. .. I got to pick up the frame and other parts from the powder coating shop yesterday! And I'm super happy with how all the parts turned out! The shop even masked off my steering stem so my bearing races got saved, I think I had the biggest smile on my face ever, and my buddy was really happy with the results as well. Anyways, enough of that, and on to the pictures! Everything came out perfectly, and with a mirror finish! For $400 blasted, primed and baked, i'm not complaining.

Woohoo! Shiney, they did a nice job.

Looking good. I don't think it will be an issue to leave the dead ends from the OEM dashboard. What I don't know is if they are ground or positive leads so make sure the are capped off. Do you have a colored wiring schematic?
Bike is really looking good sir. I will be doing some wiring today myself.

Kaw- They did a KILLER job! I had to grind a little of it off on some parts (suspension mounts, engine mounts) to get certain pieces in/make sure I get proper ground, but it sure turned out killer! I scratched a few places putting the engine in, even though I had the frame all covered in old t-shirts to protect it. Nothing that will hurt it though

I do have the wiring diagram from the original shop maintenance book. Looking at the brown wires that I was saying come from the neutral, oil, and brake, it looks like this is a ground line. It ties into a few sensors (front brake sensor, horn, ignition switch, rear brake sensor), so I can always try to ground it after if I run into issues there. The brake light indicator light looks to be only hot if the sensor ever tripped, so I'll cap that off to be safe. I've also figured out a few loose ends with the new gauge and where I have to run power from/splice into. So hopefully by this evening, I have the gauge and lights all hooked up and can do an electrical shakedown

Today turned out to be fairly productive. I ended up getting the new Acewell speedo/tach unit installed, and it lights right up No issues there. I had to split the main wiring harness to move my ignition switch wiring back as I tucked the ignition in front of the clutch side coil in the steering stem area. After that, I went right into labeling all my wiring so that I could split and splice the new speedo in. That went smoothly, and all the connectors now have shrink wrap on them to seal the weather out. The new turn signals are hooked up and working properly. The tail light is installed and works properly. The headlight works properly. The bike turns over no issue. So with all the electrical tinkering I've done, I haven't goofed anything up yet! I'm always nervous with wiring as one small mistake can turn to be such a hassle to fix.
The two lines that i was going to have to leave as "dead ends" are taped off and tucked into the harness for now.
I then started to put on some of the body work and secure the wiring harness in place. Here's a few pictures of what I got done today

This is the result of all the labeling and splicing wires. A nice rat's nest.


Hooked the battery up, turned the key and....


Lights work!


Tail end all good to go


Just taking a peek at what she'll look like











If I have enough time to tinker with it tomorrow, I'm thinking I'll have it fired up so I can start tuning the carbs up

Devin

the thing is looking awesome!


i do have reservations about the headlight mount tho, :whistle:

leon

Thanks Leon what are your thoughts on it? Let em roll. I'm thinking I'll have to shorten it up a little bit, it sticks out a little far for me to tuck all my wiring in. As always, input is more than welcome

imho,
the ears need shortened up so that the gap between the acewell and the back of the headlight is minimized.
enough air gap for adjustment but not enough room for a bedroll !!!!!!!!

thats my one nitpick :whistle: ,
this thing turned out awesome tho.
and is one of the builds on this forum that has had a major amount of modification(very well executed i might add)and is now nearing completion.

we have all seen enough unfinished projects on here it is really cool to see someone finishing one up.

it shows everyone that you can build a custom bike yourself,
with some help from friends and forum members and have a very nice piece when finished.

thanks for doing such a thorough job of documenting your build.

it is threads like this that inspire others to believe that maybe they too can build their idea of the perfect bike.

leon

Leon- I'm planning to shorten them up a bit, maybe an inch and a half or two. I need to make sure I have enough material left on them to set up my small windscreen mounts, but I'm thinking that much shaved off should be enough still I'm glad your input was just about something small like that Here I am thinking "uh oh, Leon has some bad news...".

Thanks for all the kind words, sir! It sure did turn out awesome. It was a slow build just due to time restraints, but it's finally coming together This forum, and all the amazing members on it, have saved my rear end so many times, it's not even funny. You especially Leon, thank you so much for all your input and expertise.

There's far too many unfinished bikes that would look AMAZING with the last few steps completed. Stuff like that is a shame it does not get completed. having the support from everyone here has made such a difference. Not just that, but having the welders at the shop give me tips and say go at it, its your build makes it so much more fun.

The only way to do a build like this is to document it so it makes it easier for other members. If I can make something easier on my build, why not let someone else pick up on the trick to save their rear.

Again, thanks for the kind words Leon

Devin

Devin, great job man really. I am with Leon the ears for the headlight are to long by an inch or two. The rest of the build is absolutely spot on.

650mod wrote: I do have the wiring diagram from the original shop maintenance book. Looking at the brown wires that I was saying come from the neutral, oil, and brake, it looks like this is a ground line. It ties into a few sensors (front brake sensor, horn, ignition switch, rear brake sensor), so I can always try to ground it after if I run into issues there. The brake light indicator light looks to be only hot if the sensor ever tripped, so I'll cap that off to be safe. I've also figured out a few loose ends with the new gauge and where I have to run power from/splice into. So hopefully by this evening, I have the gauge and lights all hooked up and can do an electrical shakedown

The brown wire is a positive (+) feed. Do not ground it! The brown wire sends power to the neutral and oil lights. The neutral light and oil pressure are normally open and close a ground loop when engaged. That same brown wire sends the power to the brake light switches which when activated send the power provided by the brown wire through the blue wire to the brake light. (Or at least that's how it all is on my GPz).



Later, Doug

Kaw- thanks! That's the plan for now. Mock up where I can get away with having the windscreen mounted, then cut away. It definitely will tidy it up lots Thanks for the kind words, i'm so excited to be able to fire her up soon!

Doug- with that Broan wire, do I need to hook it up to anything then? Or is just capping it off sufficient? Not having that circuit hooked up with that wire won't affect my oil pressure sensor will it? All of my lights are functional, including the running light/stop light on the tail. Do I have anything to be worried about?

Devin

650mod wrote: Doug- with that Broan wire, do I need to hook it up to anything then? Or is just capping it off sufficient? Not having that circuit hooked up with that wire won't affect my oil pressure sensor will it? All of my lights are functional, including the running light/stop light on the tail. Do I have anything to be worried about?

Devin

Is the brown lead you're talking about up by the headlight area? There's an extra lead on my 1000 up there for accessories and what not. That can just be capped off/taped over, etc. The brown wire has 4-6 branches throughout the harness normally so taping an extra one up front is no biggie.

Later, Doug